Had the 2003 TE 450 under cover for a week, got it out on Saturday and it presented symptoms of a dead battery. A weak turnover of the starter and then just a 'tick' when the starter was pressed. Tried my jump pack and same thing. Both read over 13v on the meter and power was going to the starter motor with the button pressed, so pulled the starter and bench tested it with the jump pack. It was working sporadically. Stripped it, cleaned it and put it back together, its now working fine but still sounds horrible. I can only imagine its the race bearing? But it felt fine off the bike (see video below)
Whilst the starter was out, i checked the action on the one way bearing or starter clutch. The cog had a fair bit of lateral movement which isn't right. You can also see in this picture, the starter is starting to chew the outside of the cog where its not lined up correctly.
QUESTION: The bike has a rattle which i thought was the clutch basket, but could it be this? My only reason for questioning it, is that this sits idle whilst the motor is running so i cant see how its causing the rattle, unless it literally just rattles the idle cog under load??
QUESTION 2: Should the clutch basket have any play at all? See below. is that enough to cause a rattle under load? Or is my likely suspect the starter clutch cog?
Of course I'm going to strip it down and replace parts required but was after some advice or experience?
STARTER INTERNALS -
MOVING COG (see the chewed edge)
BENCH TEST STARTER:
http://vid76.photobucket.com/albums/j31/crotchrocket3000/IMG_1544_zpsg9jfohni.mp4
STARTER NOISE:
http://vid76.photobucket.com/albums/j31/crotchrocket3000/IMG_1545_zpsxfqs69h7.mp4
CLUTCH BASKET MOVEMENT:
[video]http://vid76.photobucket.com/albums/j31/crotchrocket3000/IMG_1548_zps8y8hores.mp4[/video]
Whilst the starter was out, i checked the action on the one way bearing or starter clutch. The cog had a fair bit of lateral movement which isn't right. You can also see in this picture, the starter is starting to chew the outside of the cog where its not lined up correctly.
QUESTION: The bike has a rattle which i thought was the clutch basket, but could it be this? My only reason for questioning it, is that this sits idle whilst the motor is running so i cant see how its causing the rattle, unless it literally just rattles the idle cog under load??
QUESTION 2: Should the clutch basket have any play at all? See below. is that enough to cause a rattle under load? Or is my likely suspect the starter clutch cog?
Of course I'm going to strip it down and replace parts required but was after some advice or experience?
STARTER INTERNALS -
MOVING COG (see the chewed edge)
BENCH TEST STARTER:
http://vid76.photobucket.com/albums/j31/crotchrocket3000/IMG_1544_zpsg9jfohni.mp4
STARTER NOISE:
http://vid76.photobucket.com/albums/j31/crotchrocket3000/IMG_1545_zpsxfqs69h7.mp4
CLUTCH BASKET MOVEMENT:
[video]http://vid76.photobucket.com/albums/j31/crotchrocket3000/IMG_1548_zps8y8hores.mp4[/video]