Some 2002 and older Busas have had a history of starter "kick back" while starting under certain conditions... when bike is hot, using throttle to start, and expecially having a low battery charge.
What happens sometimes is when a "kick back" occurs, it usually screws up a lot of stuff. The most expensive thing it messes up at times is a broken case! Not good news. These things seem to be a time bomb, maybe it will, maybe it won't kind of thing.
However Schnitz Motorsports sells some cheap PROTECTION against broken cases with their Titanium ring, which fits around the part of the case that holds the idler gear shaft and idler gear. The reason for this post is because after numerous searches of every site I could find, I never really came up with good pictures of where the thing went, or really how to do it. For a rookie mechanic like me, I wanted to know more than, "Just beat the thing on!" Good product but instructions suck.
I did mine this past weekend (it's the 29th mode this winter) and here is what I learned, from "start to finish." I'm sure this isn't the definitive know all on how to do it, but it worked for me. As I said, this product should prevent the case from being broken if the "stuff" hits the fan!
Here is what we are installing... a $30 part, Titanium ring
First, remove the idler cover, then the starter clutch cover VERY carefully!
Keep up with where the bolts go... different sizes.
Once the cover is removed, here we remove the idler gear. The ring goes behind this.
Now we just pull the gear, sleeve, rear washer and wave washer straight off.
Check condition of splines and gearsfor potential problems.
With the idler gear out, ring goes here. This is the part that usually gets broken!
Here's the "not so fun" part. Use a 20mm socket to knock that sucker on. Might be awhile but it MUST BE FLUSH !
The sleeve will probably be a tight fit after this but be sure it is seated all the way. Notice the ring is flush.
New gaskets, a thin coat of liquid gasket and CAREFULLY put the cover back on. All bolts are torqued to 7 ftlbs. You are done!
Not trying to scare all us 2002 (and some older) owners, but there is a lot of information of this and other boards about this problem. If the starter frags itself, well, maybe I'll just upgrade to the 2003 system, OR just keep a well charged battery, Titanium ring and oh, I also change the wires from my battery to relay, relay to starter, and negative side of battery to starter... to 4awg wires. This should help too. Good luck!
What happens sometimes is when a "kick back" occurs, it usually screws up a lot of stuff. The most expensive thing it messes up at times is a broken case! Not good news. These things seem to be a time bomb, maybe it will, maybe it won't kind of thing.
However Schnitz Motorsports sells some cheap PROTECTION against broken cases with their Titanium ring, which fits around the part of the case that holds the idler gear shaft and idler gear. The reason for this post is because after numerous searches of every site I could find, I never really came up with good pictures of where the thing went, or really how to do it. For a rookie mechanic like me, I wanted to know more than, "Just beat the thing on!" Good product but instructions suck.
I did mine this past weekend (it's the 29th mode this winter) and here is what I learned, from "start to finish." I'm sure this isn't the definitive know all on how to do it, but it worked for me. As I said, this product should prevent the case from being broken if the "stuff" hits the fan!
Here is what we are installing... a $30 part, Titanium ring
First, remove the idler cover, then the starter clutch cover VERY carefully!
Keep up with where the bolts go... different sizes.
Once the cover is removed, here we remove the idler gear. The ring goes behind this.
Now we just pull the gear, sleeve, rear washer and wave washer straight off.
Check condition of splines and gearsfor potential problems.
With the idler gear out, ring goes here. This is the part that usually gets broken!
Here's the "not so fun" part. Use a 20mm socket to knock that sucker on. Might be awhile but it MUST BE FLUSH !
The sleeve will probably be a tight fit after this but be sure it is seated all the way. Notice the ring is flush.
New gaskets, a thin coat of liquid gasket and CAREFULLY put the cover back on. All bolts are torqued to 7 ftlbs. You are done!
Not trying to scare all us 2002 (and some older) owners, but there is a lot of information of this and other boards about this problem. If the starter frags itself, well, maybe I'll just upgrade to the 2003 system, OR just keep a well charged battery, Titanium ring and oh, I also change the wires from my battery to relay, relay to starter, and negative side of battery to starter... to 4awg wires. This should help too. Good luck!
