Stripped shaft! How do I fix it?
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  1. #1
    Senior Member PalmStateCrawler's Avatar
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    Ok. So I have been taking my ttr apart to fix the e-start. When I replaced the starter clutch, my friend Jon helped me. I believe he put the clutch on backwards because all I heard when I pressed the e-start was the spinning gears and they were all in great shape. So I pulled the flywheel today and somehow I did THIS!!!!









    How can I fix this?
    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

  2. #2
    Senior Member lizrdbrth's Avatar
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    Do you recall how many threads were exposed when the fywheel was in its original (un-disassembled) state?



    If when the nut was fully tightened you had several threads exposed you can fix it easily.



    Just carefully grind off ONLY the stripped thread and run a die down the threads. Then bring it back up the shaft to within a couple of threads of the end and square the end of the shaft with a file. SLIGHTLY knock the edge off the first thread and yer back in buisiness.



    The fun part will probably be finding a die in the same thread as the shaft. They can be hard to find in larger thread sizes outside of dedicated "tools only" shops.



    I can explain it to you, but I can't understand it for you.

    Powdercoated '87 frame, extended swingarm, YZ fork legs, ATV tire, 14/55, XT350 tank, spliced quick-release seat, disc brake conversion, beeg headlight, beeger rack, Lizrdcooler, Lizrdventz and bunch of other stuff all covered in invisible ink.

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  3. #3
    Senior Member mekdad's Avatar
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    Start with the first good thread and get a triangle file and carefully file your way around the shaft following the thread all the way to the end of the shaft through the stripped part.

    They do make thread files also maybe find one at harbor freight make sure to get a metric one. The thread file is the best way to go when doing it this way. Same process work your way around carefully to the end of the shaft.

    Ken



    PS. this has saved my arse more than once.
    You never know what you can do until you have to undo something you have done.

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  5. #4
    Senior Member PalmStateCrawler's Avatar
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    Ok. I was trying to do it with a hack saw blade but i'll just head to harbor freight tomorrow and get a file. If all else fails, I will just have to do it LBs way.



    I checked the starter clutch and it is installed properly but the gears are spinning backwards! That is why it wont engage. Any rhyme or reason to this?



    Edit: Figured it out! I took apart the starter and turned the magnets 180° and voila, it's spinning in the right direction now! Too bad I had to strip the flywheel shaft to figure this out
    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

  6. #5
    Senior Member mekdad's Avatar
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    Are the wires on backward? turning the starter motor backward.

    You got it nevermind
    You never know what you can do until you have to undo something you have done.

  7. #6
    Senior Member mhomadness's Avatar
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    I like thread repair files! They work great! Mine are made by General.



    http://www.acehardware.com/product/i...ductId=1292851



    Sorry, I still have to figure out how to put my own pictures into my posts.



    These work GREAT, and will easily fix that shaft with minimum work. I have two versions. The first one has TPI's as follows: 9,10,20,27,12,16,28,32. The second one has TPI's as follows: 13,14,16,18,11,12,20,24.



    WAY better than hack saw blades, triangle files, finger nails, teeth, etc. They can clean threads up well enough to get a die onto a shaft / bolt properly too! You don't need a die, just the files. Try to find them both, as that will insure you get the proper TPI. m.

  8. #7
    Senior Member PalmStateCrawler's Avatar
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    Thanks Mike. I'll pick one up tomorrow.
    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

  9. #8
    Member koonercat's Avatar
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    Quote Originally Posted by mekdad View Post
    Start with the first good thread and get a triangle file and carefully file your way around the shaft following the thread all the way to the end of the shaft through the stripped part.

    They do make thread files also maybe find one at harbor freight make sure to get a metric one. The thread file is the best way to go when doing it this way. Same process work your way around carefully to the end of the shaft.

    Ken



    PS. this has saved my arse more than once.


    x2...a decent triangle file may be all you need. File carefully until the nut will go on by hand.

  10. #9
    Senior Member Stromper's Avatar
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    Care and triangle file will do it.



    If not harbor freight then go to is www.mcmaster.com << all hardware in universe

  11. #10
    Senior Member PalmStateCrawler's Avatar
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    Picked up a triangle file and a thread repair file from napa. The thread repair file was 18 bucks and has 8 pitches on it starting at .75. I didn't even know those existed! Very cool. Used the triangle file to start and the thread repair file to finish it off. That definitely saved my ass. Thanks guys!

    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

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