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PostPosted: Sun Nov 24, 2013 3:04 pm 
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Adventure Rider
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Joined: Mon Jan 02, 2012 9:19 am
Posts: 682
Location: Belém, Brazil
I have just finished the replacement from Solid Idle Gear (12611-32E00) to the Starter Clutch Limiter assembly.

I had posted this elsewhere on the forum and I had some trouble finding it, so i decided to re-post here and add a few pictures and explanations to help who ever is considering a 98 or 99 model. Or someone who has one 98-99 model DR and did´t do the starter gear replacement yet.
More information is always welcome, so please post down anything you guys feel that could be helpful to the thread.

You will need, 8 mm tool, new bracers for the cables, Oil, Oil Pan, maybe a new stator cover gasket so get yourself one before you start the job. and the parts bellow.

item: 08211-10221 Quantity:2 WASHER
item: 12600-12D01 Quantity:1 LIMITER ASSY, STARTER IDLE
item: 12618-31D01 Quantity:2 BUSH, LIMITER SHAFT

This should be a very good pictorial for those who needs to check on this issue.

This is the bad guy to be removed:
Image

1 - The two parts side by side, this picture i found on the web and was looking at for identifying the part in there. Starter Clutch Limiter on the left, solid idle gear on the right.

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Page from the Clymer Manual illustrating the parts and showing the Starter Clutch limiter.

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From the Clymer manual information and using the last picture i posted from the Starter side. You can already tell its the solid gear.
So if you can take a look from the starter side you can also tell which one is in the engine.

Image

Anyway, lets take a peek inside...
2 - Drain Oil.
3 - Remove the cover screws in a way you don't lose them, and replace in the same order.

Image

4 - Remove the Cover, if doing it while changing the oil beware its going to be very hot, use some leather gloves or thick cotton cloves so you don't burn yourself and drop the cover.
Watch for the Pin in the lower left of the cover and also note you will feel a resistance from the strong magnet as you pull it out.

Very Important, don't forget to disconnect the stator cables from the CDI and the bikes wiring because they are very short, I didn't disconnected them since i had my old man to hold it for me :biggrin:.
I did remove the tie holding them together near the frame. I installed it back the same way, if it leaks I´ll replace the gasket.
Also there was a glob of dirt there i advise you clean before you close the cover again.

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5 - Several Shots of the Solid Gear and inside of the stator cover.

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Image

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Since the gasket was still in one piece, I Closed it with the same gasket.

Opening the case to check was very easy you only need a good 8mm socket or wrench. If you didn't check yours yet, do so.

By the way, the bike is 15 years old and has 32.311 miles on it with the solid gear. I've been using it daily for the last 2 years.
So don't assume yours is Ok just because you don't have any issues like I assumed. :blush:. Check and replace if needed.

I installed the torque limiter today, and followed the same procedures above to open the cover.

Took both gears out of the cover. the gear on the left shaft is going back in after the stater limiter is again on the cover. the solid gear is just a gear and a shaft. just remove it.

Image

Now be careful, the starter limiter is a assembly.

1- rinse parts with oil.
2- place the washers on both sides of the starter assembly.
3- place the bushings on both sides of the stater limiter shaft.

And while placing the assembly in the cover pay attention to the bushings! do not let them fall from the starter limiter.
The starter limiter should fit perfectly where the solid gear was. Replace the other gear after the limiter is in place and jobs done. Close up and check the oil level before starting the bike.

Image

This time my old man was giving me a hand. being a professional Stator Cover stand. a very steady one by the way. he was holding the cover while I replaced the gears, although i recommend you disconnect the cables from the wire harness and work with the cover on a workbench especially if replacing the gasket..
Image

My conclusion is that this is not a hard job to do and no reason to turn down a good deal on a 98 or 99 model, might even be a better deal just use it to bring the price down!
The bike used to do a loud "CLANK" noise when I shut it off, and now it is silent on shutdown. I´ll post a update on Friday if the new limiter really stopped the "CLANK" noise on shutdown.

_________________
In Love: 1998 - DR 650 SE. Use: 100% On-road.
Now: IMS Tank, Iridium Plugs, Deluxe fuel screw, KTM needle, Scott´s stainless steel oil filter, Zeta quick throttle tube, Sit & Fly seat cover, Ricor Shock (7.2 spring) and Marving Amacal Exhaust.
Soon: Ricor Intiminators.
Check: http://www.youtube.com/user/ViverComCoragem/videos


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PostPosted: Sun Nov 24, 2013 6:48 pm 
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Joined: Fri Sep 10, 2010 10:22 am
Posts: 9981
Location: Mackinaw City, MI, USA
Bravo Coragem! :clapping: Moving this one to the How To section for sure..... :good:

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PostPosted: Tue Nov 26, 2013 7:58 pm 
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Adventure Rider
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Joined: Mon Jan 02, 2012 9:19 am
Posts: 682
Location: Belém, Brazil
mxrob wrote:
Bravo Coragem! :clapping: Moving this one to the How To section for sure..... :good:

Thank you for moving it to the correct section Rob. I hope it can be useful to someone in the future.
I´m pretty happy with the job so far. Even though i opened the stator cover twice, the gasket is still working ok and not leaking at all. :good:

_________________
In Love: 1998 - DR 650 SE. Use: 100% On-road.
Now: IMS Tank, Iridium Plugs, Deluxe fuel screw, KTM needle, Scott´s stainless steel oil filter, Zeta quick throttle tube, Sit & Fly seat cover, Ricor Shock (7.2 spring) and Marving Amacal Exhaust.
Soon: Ricor Intiminators.
Check: http://www.youtube.com/user/ViverComCoragem/videos


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PostPosted: Sun Jul 31, 2016 8:53 am 
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Single Tracker
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Joined: Sun Mar 27, 2016 6:13 pm
Posts: 209
Location: Ashland, MO
I know this is old, but just wanted to say thanks for posting! I'm looking into doing this myself. I figured it would be easy enough, but never a bad thing to see the procedure ahead of time to see exactly what you'll be working with.


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PostPosted: Sun Jul 31, 2016 10:10 am 
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Joined: Fri Sep 10, 2010 10:22 am
Posts: 9981
Location: Mackinaw City, MI, USA
G Steezy wrote:
I know this is old, but just wanted to say thanks for posting! I'm looking into doing this myself. I figured it would be easy enough, but never a bad thing to see the procedure ahead of time to see exactly what you'll be working with.

:2_thumbsup:

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