1997 Voyager Xii: Splitting Engine Cases.... Starter Clutch
Moderators: the2knights, Highway Rider
-
- Newbie
- Posts: 6
- Joined: Thu Jul 26, 2012 3:29 pm
- 12
- Current bike(s): 1997 Voyager XII
1976 KZ900 - Has liked: 0
- Been liked: 0
1997 Voyager Xii: Splitting Engine Cases.... Starter Clutch
Hey all,
NOTE: I have sent an e-mail to Carl as well but wanted to see if anyone has run into this hang up while splitting the engine cases.
First off, total PITA just for the damn starter clutch (excessive slippage)... Here in AZ, so hot these days don't feel like riding so no better time to get the starter clutch swapped out....
I have the engine out of the frame, all case bolts and associated components removed and can get the cases apart everywhere but one place....
As can be reviewed in the image, catching/hanging up in the lower case under the flywheel and I can't see anything that would be catching nor any additional bolts (external or internal) that would not allow for the cases to split...
Everywhere along the cases no issues, only in this spot where it will only split apart ~ 3/8ths " and that's it....
Anyone have experienced this or have an idea...?
Thanks,
Dave
Damn image insertion.....
NOTE: I have sent an e-mail to Carl as well but wanted to see if anyone has run into this hang up while splitting the engine cases.
First off, total PITA just for the damn starter clutch (excessive slippage)... Here in AZ, so hot these days don't feel like riding so no better time to get the starter clutch swapped out....
I have the engine out of the frame, all case bolts and associated components removed and can get the cases apart everywhere but one place....
As can be reviewed in the image, catching/hanging up in the lower case under the flywheel and I can't see anything that would be catching nor any additional bolts (external or internal) that would not allow for the cases to split...
Everywhere along the cases no issues, only in this spot where it will only split apart ~ 3/8ths " and that's it....
Anyone have experienced this or have an idea...?
Thanks,
Dave
Damn image insertion.....
- Gator Mike
- Traveler
- Posts: 219
- Joined: Mon Feb 18, 2008 12:39 am
- 16
- Current bike(s): 1994 Kawasaki voyager
2002 Honda 750 ACE
1969 Honda 90 - Location: Elton, Louisiana
- Has liked: 0
- Been liked: 0
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
Dave do you have a manual? I split the case on mine about a year ago and we missed a bolt near where the starter is located. After we had trouble we used the manual which pointed out the location of all the bolts. It's amazing how well it went when we followed directions Anyhow I don't know if that's your problem because once the bolts were out it split real easily. Good luck with what ever it is..........Gator Mike
"Laisez les bon temps rouler!"
1994 Voyager XII
2001 Honda Ace
1969 Honda CM91
Louisiana Patriot Guard Rider
Combat veterans motorcycle Association
1994 Voyager XII
2001 Honda Ace
1969 Honda CM91
Louisiana Patriot Guard Rider
Combat veterans motorcycle Association
-
- Newbie
- Posts: 6
- Joined: Thu Jul 26, 2012 3:29 pm
- 12
- Current bike(s): 1997 Voyager XII
1976 KZ900 - Has liked: 0
- Been liked: 0
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
Yup OEM manual (only way to go).... No mention of the hang up so spoke with Carl (great guy)....
Anyway, turns out the flywheel does indeed have to come off....
Starter clutch already swapped out... Old one spins both ways by hand... DOH!
Tranny gears, bearings, clutch components, oil pump components etc... all look good.
Cleaning grime off cases/pan while putting her back together... Images to follow etc....
For those that may need.... $14 tool to get the flywheel off, worked like a charm!
Anyway, turns out the flywheel does indeed have to come off....
Starter clutch already swapped out... Old one spins both ways by hand... DOH!
Tranny gears, bearings, clutch components, oil pump components etc... all look good.
Cleaning grime off cases/pan while putting her back together... Images to follow etc....
For those that may need.... $14 tool to get the flywheel off, worked like a charm!
-
- Newbie
- Posts: 6
- Joined: Thu Jul 26, 2012 3:29 pm
- 12
- Current bike(s): 1997 Voyager XII
1976 KZ900 - Has liked: 0
- Been liked: 0
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
Made some progress, almost there....
Starter Clutch replaced, yup old one is toasted...
Engine Cleaned...
Hate Working on oily/greasy/grimed crap....
Carbs cleaned inside & out...
Water Pump Oil Seal.... Seep hole is where she leaked pass seal...
DIY Flywheel holder for 110 ft/lbs torque....
Now it's install the exhaust, radiator w/coolant and starter her up....
New Pirelli Route rear tire going on as well!
Final completed images later....
Starter Clutch replaced, yup old one is toasted...
Engine Cleaned...
Hate Working on oily/greasy/grimed crap....
Carbs cleaned inside & out...
Water Pump Oil Seal.... Seep hole is where she leaked pass seal...
DIY Flywheel holder for 110 ft/lbs torque....
Now it's install the exhaust, radiator w/coolant and starter her up....
New Pirelli Route rear tire going on as well!
Final completed images later....
-
- Cruiser
- Posts: 46
- Joined: Mon Oct 31, 2011 7:12 pm
- 13
- Current bike(s): 1978 Kawasaki KZ1000 Ltd
1991 Kawasaki Voyager XII - Has liked: 0
- Been liked: 0
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
Your links don't seem to be working on this site, (at least for me).But I saw your post on KZR. Awesome work, You really took that baby down! Very nice work on the exhaust headers. Too bad you can't see them when it's all together. BTW, it looks like you could be the anchor man on the KZR relay.
-
- Newbie
- Posts: 6
- Joined: Thu Jul 26, 2012 3:29 pm
- 12
- Current bike(s): 1997 Voyager XII
1976 KZ900 - Has liked: 0
- Been liked: 0
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
Anyone else able to review...?
OK., shrunk the images down, lets see if this works.... NOPE...
"It was not possible to determine the dimensions of the image..."
Ah well.... Put the header on, no starter clutch slippage, purred right to life!
OK., shrunk the images down, lets see if this works.... NOPE...
"It was not possible to determine the dimensions of the image..."
Ah well.... Put the header on, no starter clutch slippage, purred right to life!
-
- Cruiser
- Posts: 46
- Joined: Mon Oct 31, 2011 7:12 pm
- 13
- Current bike(s): 1978 Kawasaki KZ1000 Ltd
1991 Kawasaki Voyager XII - Has liked: 0
- Been liked: 0
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
The most satisfying push of a button you'll ever have!oldmanrock wrote: Ah well.... Put the header on, no starter clutch slippage, purred right to life!
-
- Newbie
- Posts: 6
- Joined: Thu Jul 26, 2012 3:29 pm
- 12
- Current bike(s): 1997 Voyager XII
1976 KZ900 - Has liked: 0
- Been liked: 0
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
OK trying this image posting from an online image sharing....
Image URL link for exploded view..... Image link for small forum views....
http://postimg.org/image/bdyzo0ecx/
http://postimg.org/image/p48oo4x9p/
http://postimg.org/image/86e9g1d9p/
http://postimg.org/image/k9jl3lobx/
http://postimg.org/image/523lj8wh9/
http://postimg.org/image/yq294fofh/
Image URL link for exploded view..... Image link for small forum views....
http://postimg.org/image/bdyzo0ecx/
http://postimg.org/image/p48oo4x9p/
http://postimg.org/image/86e9g1d9p/
http://postimg.org/image/k9jl3lobx/
http://postimg.org/image/523lj8wh9/
http://postimg.org/image/yq294fofh/
- doug of so fla
- Grand Tourer
- Posts: 431
- Joined: Tue Feb 19, 2008 6:17 pm
- 16
- Current bike(s): 07 gold wing
- Location: summerfield, fl
- Has liked: 0
- Been liked: 1 time
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
Photo's came out great!!! Be sure to post finished product!! Looks like it will be perfect when done.. You will like the XII a whole lot better after you do a job like that, knowing everything is done right... congrats...
doug of no fla
- Chris near Kansas City
- Elite Tourer
- Posts: 645
- Joined: Mon Feb 18, 2008 3:01 am
- 16
- Location: Do I have to spell it out for you?
- Has liked: 0
- Been liked: 1 time
Re: 1997 Voyager Xii: Splitting Engine Cases.... Starter Clu
Few have ventured so far....
"You only live twice, or so it seems. One life for yourself and one for your dreams...." Nancy Sinatra
"If a man made it, a man can fix it." - Steve in Sunny Fla
"If a man made it, a man can fix it." - Steve in Sunny Fla