>
> --- In
DSN_KLR650@yahoogroups.com, "Tom Zangla" wrote:
> >
> > Yesterday I adjusted the Do Hickey bolt as I have done before many
> > times on my A19 with 10,000.miles. When I started it I heard a
> > Klunk Klunk right after the engine started and I left off of the
> > starter button. I do not recall hearing this klunk klunk before.
> > Could the Do Hickey bolt adjustment cause this or could there
> > be something going wrong with the starter?
> > Tom
> > SW Pennsylvania
> Tom,
>
> How did you adjust it? Only loosen 1/2 turn 1 turn, just enough for
> the lever to move?
>
If you loosen it too much, it can slide down the shaft and
> then bind out of position when you tighten the bolt. If this happens
> the big starter gear can hit the lever when the starter switch is
> pressed. This gear only turns when the starter is working.
> all the best,
>
> Mike
> Eagle Mfg since 1990
Tom,
I rec'd your email - I'll post the reply to the list so someone else
that's doing it by the manual can see the info. I understand that you
still have the stock parts, and extended warranty.
The manual says "loosen the bolt a few turns." If it is loosened and
slides down the shaft, it can bind on the shaft and not re-seat
properly. This is because the adjustment (clamping) bolt for the lever
is not in the middle of the shaft is locates. If this has happened,
and you get the knocking noise, you need to remove some parts to check
things out. Or... go see the dealer. This might or might not help, as
I've heard several stories of difficulties with dealer service areas....
Remove the countershaft cover - 3 bolts, 10mm socket and ratchet.
Remove the shift lever, 10mm wrench
Remove the bash plate, 3 bolts, 10mm socket and ratchet (if still stock.)
Drain the oil, or lay the bike over on the right side far enough the
oil won't run out.
Pull the green neutral wire loose from the case by the sprocket.
Wiggle the wires out of the channel in the case by the sprocket.
Remove the bolts holding the outer case, (10?) 8mm socket and ratchet.
Carefully pull the case straight out. Watch out for loose parts and
gaskets. Don't tear the gasket unless you have a spare.
You can now see the adjustment bolt, and where it clamps the bottom
edge of the lever, below the rotor. Loosen the bolt and wiggle the
lever a bit. You should feel spring tension pushing the bottom edge
forward. If not, you have a broken spring. Look for damage on all of
the lever you can see. Try to re-seat the lever and gently tighten the
bolt.
Diagonally up to the right from the rotor are a couple of small gear
sets. Remove the one closest to the rotor. There should be a small,
thin thrust washer on the inner and outer side of the set. While this
set is removed, try to turn the big starter gear behind the rotor
clockwise. It should turn without hitting anything. If it hits at this
point, you'll need to remove the rotor and replace the balancer
lever/hickey. If it doesn't hit, put the gear set back, and assemble
in reverse order. You might have to rotate the big gear a bit to allow
the gear seat to fully seat, since it was moved.
Send me your number, or call me if you get stuck, need more help, etc.
all the best,
Mike
Eagle Mfg since 1990