What puller to remove the magneto flywheel on a gs450?

[dennco2]

A new starter motor relay solenoid has been installed .... and performs fine. The old relay was unreliable and would stay in the ON position sometimes. Since pulling the magneto flywheel and inspecting and reassembling the 3 steel clutch bearings, the starter clutch has been working fine too. When I finally was able to pull the magneto flywheel and look at the 3 roller bearing .... 2 of them had fallen out of their correct position. Don't know if they were like that before .... or by me holding the whole assembly in the wrong position after removal from the shaft.

Doing short rides as I don't trust the bike for reliability as yet. The 2 issues mentioned are seemingly fixed! Now I have to check the voltage being generated with engine at 4,000 rpm and see if the stator & R/R system is charging the battery while running. I also have ordered a used SH775 for my gs450 if needed .... or will put it in my GR650 Suzuki which also has a charging problem ... not yet looked at. One bike at a time.

[dennco2]

I have ordered another starter relay and it should arrive next Saturday. By next Sunday, I hope to have this problem solved and will report back hopefully with good news.

[dennco2]

In a test ride a week ago or so, I could feel a drain in engine power and I believe the starter clutch was intermittently grabbing on to be driven direct drive by the engine. It would grab and release and grab again, along with an annoying howling, growling noises and spinning up the starter motor. On this trip however, I did not feel grabbing friction. All I felt was at low idle, the engine wanted to die but couldn't because the starter motor was always spinning. When I pulled into my driveway and turned off the ignition .... the starter was still turning the engine and would not stop till I pulled the battery ground.

[tom203]

?Every time I slowed the engine to idle I would feel the engine lurching and could HEAR the starter motor?

when you eventually turned bike off, did you hear the starter running? Or do you think when bike was running, the non energized starter motor was being ?dragged? around by a locked up starter clutch? The starter clutch might have jammed up due to the starter motor issue before. Sadly, you better remove stator cover and investigate starter clutch again...it needs to release the big gear or unpleasant noises plus bonus events will ensue.

[dennco2]

The solenoid big wire is connected direct to battery +....if solenoid is faulty, once activated by button, it ?locks? on .....it doesn?t care about ignition being ?off?

Okay, makes more sense to me now. I started the engine today and all sounded normal at idle ... so a half hour later I took the bike out for a short ride. When starting the engine for that ride, the extra noise returned but I rode the bike keeping the rpms quite low. Every time I slowed the engine to idle I would feel the engine lurching and could HEAR the starter motor running and adversely affecting the engine idle and smoothness.

My starter solenoid relay is definitely bad and I will order one ASAP. Otherwise, the engine ran quite normal altho I didn't really test high rpms. I would love to start riding this bike reliably and not have to fix things!!!

[tom203]

The solenoid big wire is connected direct to battery +....if solenoid is faulty, once activated by button, it ?locks? on .....it doesn?t care about ignition being ?off?

[dennco2]

Yes, the starter relay solenoid must be hanging up in the ON position. I don't understand how the starter motor would keep running after I turned OFF the ignition?? There was no stopping that thing short of pulling off the battery ground. Might have to order another solenoid, but I am going to try again today to see if I can assess what is happening when the engine starts ... and identify the extra noises it is making especially at idle.

[tom203]

First: the green/yellow wire at starter solenoid is the trigger wire from starter button. The black/white is the ground wire for the solenoid frame. For now you better disconnect the green/yellow wire till you find out why the starter motor keeps cranking.....it?s possible that solenoid is staying locked on internally.

Second: when you press starter button , the starter motor spins the big gear, which spins the rotor thanks to starter clutch grab rollers. But as engine speeds up, the starter clutch ?releases? the big gear which stops revolving with the rotor.....but the big gear,idler gear,and starter motor all stay in mesh...but they no longer revolve.

[dennco2]

I put all parts back on the bike I had removed to pull the rotor flywheel and inspect the stator and starter clutch. I installed the charged battery and the engine started immediately. I kept the rpms low and at idle especially there was a clattering noise. I then turned off the ignition .... and the engine kept running with the starter still ON and cranking! ... I tried the kill switch and the starter kept turning over the engine but not firing. The starter motor kept cranking the engine until I finally unscrewed the ground side of the battery. I used a loose fitting rubber boot over the + side of the battery which can make contact with the top of the battery box just sitting there.

I checked the starter button, and it seems to operate properly with the coil spring contact release. So it appears I have starter motor that keeps running all the time and also the starter clutch doesn't release the starter to the crankshaft ... so the starter motor gets driven direct drive by the engine!

This time I also traced the stator wires past the R/R on the left side and loops back to it. I pulled those (5) connectors apart and cleaned best I could. Tried to be super careful to mate the same color wires back together. Back at the starter relay, I wasn't 100% positive the green/yellow wire in on the right .... and the black and white wire to the left?

It appears my clutch lever has been disabled as a deterrent to starting. As I recall, I don't have to pull the handle to get a start. Anyway, does anyone reading this know why my starter motor keeps cranking .... and my starter clutch doesn't release the starter after engine start? When I tested the starter clutch operation by turning the big gear in clockwise rotation ... it also spun the starter motor. Are those starter gears supposed to disengage or stay connected teeth to teeth all the time?

No it looks ok....But testing it while running it is the only way to be sure

I'd at least test the leads for resistance to ground and for continuity across each other. You can't always see a broken wire or a short.

But it looks healthy and will be on easy street with an sh775.

[tom203]

This appears genuine with the correct Polaris part#.....but doublecheck with seller that it?s marked sh-775

https://www.ebay.com/itm/2013-Polaris-Ranger-800-Crew-Cab-Voltage-Regulator-4012941-/324548503859?_trksid=p2349624.m46890.l49286

[Grimly]

What is the best source to get the SH775 part at a good price? Any clones knockoffs to be aware of?

Ebay seller powersportsnation is a good source of genuine used ones.
There are several more though, just be sure you can see the genuine Shindengen markings on the pics.
This one here is selling off New Old Stock genuine ones.

https://www.ebay.com/itm/SH775-regulator-rectifier-Bombardier-Sea-Doo-Can-Am-Ski-Doo-Kawasaki-710001103/264150184887?epid=1128258501&hash=item3d8093f3b7:g:FmwAAOSwm~1cQ2u2

Here's a good used one...

https://www.ebay.com/itm/Shindengen-SH775-Voltage-Regulator-Rectifier-Can-Am-Polaris-Harley-Davidson/274762923511?hash=item3ff9257df7%3Ag%3AWQ8AAOSwwrhgeuRZ&LH_ItemCondition=4

[dennco2]

What is the best source to get the SH775 part at a good price? Any clones knockoffs to be aware of?

[tom203]

No it looks ok....But testing it while running it is the only way to be sure

[dennco2]

If your stator windings appear toasted, I?d opt for replacement...especially if you noted low voltage readings in the past. Here?s my previous stator...note the small cooked section. This was enough to prevent a charging voltage greater than 13.5 at any rpm.
[ATTACH=CONFIG]62709[/ATTACH]

edit: hopefully you noted the preaching about getting a SH-775 r/r

I took a picture of the stator when it was off. Do you see anything abnormal in this pic? stator4.jpg