[Sammer]

Hello, I'm new today (7/29/22). Have an 08 Ninja 500R, only 14kmi. Unfortunately it doesn't start up. Having starter clutch issues, I think. Just spins. Used to be, engine cold starter engages, engine hot will require a few tries. Now cold or hot, just spins. Looking for ideas. About to get my hands dirty.
Anyway, looking forward to getting on the road again, love riding that bike.

 

[yorkie]

hi and welcome. your going to have to take the flywheel cover off, then with it off press the starter and see what is or isn't working. could be several issues in there. depending on what it is doing.

 

[Sammer]

Thanks, was wondering about being able to start it with the cover off. Ordered a flywheel puller today. Hope it's not too difficult. I have an impact wrench, but I hope it's not necessary. From previous reading it looks like I'll need a torque wrench too.

 

[bpe]

 

[yorkie]

Thanks, was wondering about being able to start it with the cover off. Ordered a flywheel puller today. Hope it's not too difficult. I have an impact wrench, but I hope it's not necessary. From previous reading it looks like I'll need a torque wrench too.

hello again, yes you can no problem, with the cover off you will be able to see the starter motor turning and the action of the sprocket behind the flywheel with it off, you will need a drip tray under there as it contains oil (about half a cup full) just for this job a torque wrench is not required because the centre flywheel bolt is a left hand thread (so self tightening) and just needs to be nipped up and the cover bolts have such a low torque (couple if pounds/inches) anything of a size will be far too big and strip the bolts or snap them again just nip them up. if you need one later by all means get one but be careful of the range they are not all the same or as useful as you may think.
I would also suggest you get a manual for it (if you don't have one) all the specs are in there as well as all other info.

 

[Sammer]

I was wondering how to get the flywheel cover off without scratching it. I have all the bolts off to the flywheel cover, and removed the plastic chain cover and the kick stand. The cover is stuck to the engine pretty good and using just my hands doesn't get it to budge. One other thing, you know where the connector to the stator is located? It probably will need to be disconnected after removing the flywheel cover. Thanks!

 

[yorkie]

providing you have removed all the bolts from the case it will probably be stuck with RTV and hung up on the locating dowels tap the case with a rubber/wooden mallet to shock it lose.
ps, don't forget you have a strong magnet on the flywheel trying to keep the stator in place.
the connector for the stator is hidden up behind the left hand carb (near the air box).

 

[Sammer]

That worked. Got the flywheel cover off and cables disconnected. Had to remove the rear left fender to get at the cable connectors, but no big deal. Then after a little clean up, I attempted to start it up.
The starter clutch catches for a bit and then just spins, no flywheel action.
I think my starter clutch is the problem. Either needs new parts or to be replaced.
What do you think? Time to pull the flywheel? Thanks!

 

[yorkie]

yup looks like it, oh and don't forget that centre flywheel bolt is a left hand thread, ie unscrews clockwise.

 

[ducatiman]

I'd give each of the 3 (equivalent to bic pen) springs in the starter clutch a good pull to lengthen them a bit first then give starting another go.

 

[Sammer]

I'd give each of the 3 (equivalent to bic pen) springs in the starter clutch a good pull to lengthen them a bit first then give starting another go.

I finally pulled the flywheel and took a look at the starter clutch springs, pins, and rollers. Unfortunately, they look Ok. The springs are not deformed in any way. They are all the same length. And, while the parts were in the clutch, I was able to move by hand the rollers in and out. I did notice some wear in clutch area where the rollers were. I think that may be normal, not sure if that would keep the clutch from working.
I haven't removed the clutch from the flywheel. Should I? Is there anything else I should look at? I'm really bummed out after removing flywheel and not noticing anything wrong. I must be missing something.

 

[yorkie]

have you removed the starter sprocket and chain from the engine. if not so do, inspect the sprocket for broken welds. if you can't see any (while the flywheel is off) place the flywheel face down on something flat then fit the sprocket to the starter clutch.
now if the clutch is working you should be able to turn it one way only (Clockwise) turning it the opposite way the clutch should grab and spin the flywheel on the flat surface.
the whole idea of the starter clutch is that it grabs the sprocket while starting but spins free once the engine has started.
if it's not grabbing the sprocket there is your problem. "note" make sure the starter motor is turning the correct way (clockwise) when you prod the starter button.

 

[fog]

Check the weld of the clutch drum to it’s hub if it’s only welded in 4 spots get it re welded all the way around
Fog

 

[Sammer]

Check the weld of the clutch drum to it’s hub if it’s only welded in 4 spots get it re welded all the way around
Fog

I just looked and didn't see any welds. Do I need to remove the starter clutch from the flywheel to inspect the welds? The 3 hex screws.

 

[fog]

Yes

Fog

 

[Sammer]

Ok, removed the starter clutch from the flywheel. Had an issue with one of the screws. Had to get a 6mm hex impact socket to remove it. Then took a close look at the starter clutch and could not find any welds. And, it doesn't look like the clutch cover moves at all from the drum. I put the spring, pin, and roller back into the clutch and the clutch back onto the sprocket hub to test the rotation with my hand. The clutch appears to grab the hub in one direction and not the other, like what it supposed to do. I haven't removed the starter chain yet. Was thinking of doing so to see if I can rotate the shaft by hand with the clutch. Any ideas?

 

[bpe]

Have you confirmed that the starter motor is spinning clockwise?

 

[Sammer]

Have you confirmed that the starter motor is spinning clockwise?

I just pulled the chain guide, starter small and big sprocket, and chain. I tested the starter and it was spinning clockwise. I'm perplexed. Everything looks good. I'm thinking about purchasing a new clutch sprocket (big one) and starter clutch on ebay. About $70 from caltric. Says it fits my bike (06 Ninja 500r). What do you think?
One other thing. I read somewhere that a bad solenoid may (rarely) cause the starter clutch spinning without engaging the drive shaft. You think that's possible?
Thanks!

 

[bpe]

It's not a bad solenoid.

 

[Sammer]

My new Caltric starter sprocket and clutch arrived today. Still waiting on the inch per lb torq wrench. Noticed the springs on the new clutch are more firm then the old clutch. Thinking about soaking the new clutch and sprocket in motor oil before reassembly. You think that's a good idea? The parts are dry. Thanks.