Many Unique Questions...With Pics...

[Stinger]

I tore my engine down for a re-ring and new clutch...It just keeps getting worse though.

 

First I found the piston hitting the head just barely:

 

New crank/bearings, pistons, and a.030 overbore should fix that.

 

Then I pulled my shift star to modify it for easier shifting. Behind the star I found these 5 grooves:

 

Are they "normal" or is something out of alignment?

 

Next, I found this broken washer in the bottom of the clutch case:

 

I think it goes on the shaft I'm holding it next to. Question is, why did it lodge itself in the gears on the clutch basket (I can see some teeth are screwed up) and where do I get a new one? What is it even called?

[BigRed350x]

Damn dude. Go to a site like Albaaction.com and look at their parts teardown and see what it is. That's all I can think of, short of looking at someone elses stuff.

[Wallrat]

Did you get your head milled? Cuz it ain't even. Notice the combustion chamber lip - it should be equal depth all the way around. That's why your piston was hittin the top.

[thegroup]

Did you get your head milled? 

457929[/snapback]

i think ur right on that one. if u look hard enough, u can see the smoothing marks. somebody fucked up

[crazywheelerman365]

what you have there is called a claw washer , it goes on the shaft in the picture with the gear ! you can get the part at your dealer , there only a few bucks, however you will also need to purchase a sir clip that goes over the claw washer to hold it on . also i would highly recomend purchasing a new idler gear (thats the one in the picture) the brass on the inside wears out , the gear cocks sidways and POOF !! thats what caused this to malfunction! the gear is 30 to 40 bucks but you will want one because it will do this again .

[Stinger]

Did you get your head milled?  Cuz it ain't even.  Notice the combustion chamber lip - it should be equal depth all the way around.  That's why your piston was hittin the top.

457929[/snapback]

 

Head is milled but what you are seeing is an illusion. I just went and looked at the head and it's level. There was ~.030 taken off of it so there is only a lip of about .010 left all the way around and it goes all the way. I think what the pic is showing is that the chamber was slightly off center with the jug and the carbon is partially on the milled part of the head (which appears to be the "high" side if it were milled crooked).

[Stinger]

what you have there is called a claw washer , it goes on the shaft in the picture with the gear ! you can get the part at your dealer , there only a few bucks, however you will also need to purchase a sir clip that goes over the claw washer to hold it on . also i would highly recomend purchasing a new idler gear (thats the one in the picture) the brass on the inside wears out , the gear cocks sidways and POOF !! thats what caused this to malfunction! the gear is 30 to 40 bucks but you will want one because it will do this again .

457932[/snapback]

 

Now that is some good info!. I checked out the brass and sure enough, it's loose on the shaft...

[Stinger]

Only question left is about the grooves behind the shift star...anybody know if those are normal or not?