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Post subject: 98-99 Solid Starter gear to Starter Clutch Limiter (How To) Posted: Sun Nov 24, 2013 3:04 pm

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98-99 Solid Starter gear to Starter Clutch Limiter (How To)

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Coragem

Adventure Rider

Joined: Mon Jan 02, 20129:19 amPosts: 668Location: Rio de Janeiro, BrazilLocation: Rio de Janeiro, 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 whoever 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 partsbellow.

item: 08211-10221 Quantity:2 WASHERitem: 12600-12D01 Quantity:1 LIMITER ASSY, STARTER IDLEitem: 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:

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 idlegear on the right.

98-99 Solid Starter gear to Starter Clutch Limiter (How To) :... http://drriders.com/topic10325.html

1 of 9 19/03/15 12:33

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

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.

98-99 Solid Starter gear to Starter Clutch Limiter (How To) :... http://drriders.com/topic10325.html

2 of 9 19/03/15 12:33

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.

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 yourselfand 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 .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.

98-99 Solid Starter gear to Starter Clutch Limiter (How To) :... http://drriders.com/topic10325.html

3 of 9 19/03/15 12:33

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

98-99 Solid Starter gear to Starter Clutch Limiter (How To) :... http://drriders.com/topic10325.html

4 of 9 19/03/15 12:33

98-99 Solid Starter gear to Starter Clutch Limiter (How To) :... http://drriders.com/topic10325.html

5 of 9 19/03/15 12:33

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. . 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.

98-99 Solid Starter gear to Starter Clutch Limiter (How To) :... http://drriders.com/topic10325.html

6 of 9 19/03/15 12:33

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 levelbefore starting the bike.

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 thegears, although i recommend you disconnect the cables from the wire harness and work with the cover on a workbench especially if replacing the gasket..

98-99 Solid Starter gear to Starter Clutch Limiter (How To) :... http://drriders.com/topic10325.html

7 of 9 19/03/15 12:33

Post subject: Re: 98-99 Solid Starter gear to Starter Clutch Limiter (How Posted: Sun Nov 24, 2013 6:48 pm

Post subject: Re: 98-99 Solid Starter gear to Starter Clutch Limiter (How Posted: Tue Nov 26, 2013 7:58 pm

Board index » Main Trail » Technical Tips, Tricks & Maintenance » "How To" Section All times are UTC - 5 hours [ DST ]

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 theprice 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 (7.2spring) and Marving Amacal Exhaust.Soon: Ricor Intiminators.Check: http://www.youtube.com/user/ViverComCoragem/videos

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mxrob

Member Servant

Joined: Fri Sep 10, 201010:22 amPosts: 6164Location: Kentwood, MI, USA

Bravo Coragem! Moving this one to the How To section for sure.....

_________________- mxrob -

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Coragem

Adventure Rider

Joined: Mon Jan 02, 20129:19 amPosts: 668Location: Rio de Janeiro, BrazilLocation: Rio de Janeiro, Brazil

mxrob wrote:

Bravo Coragem! Moving this one to the How To section for sure.....

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.

_________________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 (7.2spring) and Marving Amacal Exhaust.Soon: Ricor Intiminators.Check: http://www.youtube.com/user/ViverComCoragem/videos

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98-99 Solid Starter gear to Starter Clutch Limiter (How To) :... http://drriders.com/topic10325.html

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