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Discussion Starter #1
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?
 

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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.
 

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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.
 

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Discussion Starter #4
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
 

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Are the wires on backward? turning the starter motor backward.

You got it nevermind
 

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I like thread repair files! They work great! Mine are made by General.



http://www.acehardware.com/product/index.jsp?productId=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.
 

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Discussion Starter #7
Thanks Mike. I'll pick one up tomorrow.
 

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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.


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

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Discussion Starter #10
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!


 

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Discussion Starter #11
Before:





After:

 

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Discussion Starter #12
Theres always something... I fixed everything, put it back together, started it up and.... CLUNK! The cam shaft/chain sprocket broke
The tab sheared right off. I cant figure out how or why this happened but I immediately shut it off to find the problem. Hopefully the stealership wont try to rape me on the price so I can fix it tomorrow. I really hope it doesnt just do the same thing again!



... and my brand new battery that has been sitting in the bike for about 35 days now, unused, is dead. I even put the battery tender on it every weekend to ensure this didnt happen. Hopefully chromebattery will send me another one for free. (fingers crossed)
 

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Something has gotten loose and caught in the cam chain / sprocket I'd wager. Same thing happened to me many years ago, it was a tapper nut I had not tightened down.
 

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Ugh!! You have my condolences Palm State Crawler! Sometimes a guy just can’t catch a break. I’ll keep my fingers crossed for you, I don’t know exactly what I’d do in your place, is there any space to get one of those flexible magnets down & around where you need to get to? Grasping at straws, I know. Sorry.



But, I must give you the MHOM Gold Star on the thread repair, looks great! I can tell you took your time & did a good job. Cool tool eh?



Wish I had a better idea for the cam chain prob. Let us know what happens. m.
 
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