Trick to reinstall starter gear (between starter and starter clutch)

[oregonjake]

What's the trick to installing the gear between the starter gear and the starter clutch? You know, the one with the small gear for the starter and the bigger gear for the starter clutch? I am unable to line up the hole or get the washer that sits behind the gear onto the pin that holds everything aligned and together (am I explaining this right?) How does one do this? Thanks.

[loud et]

I don't recall ever having a problem. It just slides on. Maybe you should remove the starter.
That or maybe you need to put the bike in gear and push it forward to bump the starter clutch gear to move a tiny bit. (If that even moves like that)
Like I said, I've never had a problem. The washers and mid gear seem to slip right on.
Remove the starter is my guess.

[posplayr]

A little grease for the washers?

[tkent02]

You're not doing it right. Put the gears loosely in where it goes, hold it there without the shaft. Then slide the shaft through the gears, then last thing put the little washer on.
It's easy once you figure it out.

[tkent02]

What's the trick to installing the gear between the starter gear and the starter clutch? You know, the one with the small gear for the starter and the bigger gear for the starter clutch?

Actually you have it backwards, the big gear for the starter, the small gear goes to the starter clutch. The whole thing is a reduction gear.

[oregonjake]

Two pictures to help.

[oregonjake]

You're not doing it right. Put the gears loosely in where it goes, hold it there without the shaft. Then slide the shaft through the gears, then last thing put the little washer on.
It's easy once you figure it out.

I cannot line up the hole in the midgear with the hole in the crankcase. Therein lies my problem. If they lined up it would be easy. I guess I'm just not seeing how to line them up.

[tkent02]

Are you sure all three of the pieces came off the same size engine?

[JTGS850GL]

Are you sure all three of the pieces came off the same size engine?

Ya, something doesn't look right. Gears should be meshing better. Never had a problem with reassembly using the correct parts.

[tom203]

Is this a different starter motor? If so, does it have different number of teeth than original?

[tkent02]

Hard to tell from these pics, but are the teeth on the starter all smushed up and is that preventing the gears from meshing correctly??

[JTGS850GL]

It does look like the starter gear is the problem. Doesn't look like those teeth are going to mesh. Pitch looks to small on the starter gear.

[oregonjake]

Got it! I guess the pictures looked a little funny because the gearset was just being held in place with my fingers, it was not installed as you can see, the pin was not installed. I managed to get the starter clutch to turn just enough so the hole lined up by turning the rotor using the nut holding it on the end of the crank, thus relieving the pressure from the starter clutch enough to move it less than 1/4 inch. That was enough for everything to line up.

Whew! Thanks all for the quick response, I can always count on you to come through when needed. Thanks a bunch!

[JTGS850GL]

Funny how picture angles can change your prospective of things.