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 minarelli 50cc starter clutch clank 
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Post minarelli 50cc starter clutch clank
well, ive replaced the crank in my motor and i go to put the starter back on and when i hit the start button and the starter turns...i hear a clanking sound coming from it. anyone have any ideas? ive got a few questions about where some washers go....

entire assembly:
Image

here is the gear that the starter spins, which in turn spins the starter clutch assembly...but which order do these washers go?

both on "outside"?
Image

one on inside, one on outside?
Image

both on inside, none on outside?
Image

when they are both on the outside, there is less of a clanking noise but even then, i can reach back behind the whole thing and wiggle the starter sprocket a little bit...

here is the "bearing" just hanging:
Image

it then goes on the "support"
Image

here is the "inside" of the sprocket with the spacer that goes up against my crank seal:
Image

and then here is the entire assembly. as you can see, i dont have any room after putting the castle nut on the crank to put any spacers to push the variator more onto the starter clutch, to push that starter clutch more onto the starter sprocket.
Image

any ideas? also, sorry for the picture sizes...i didnt think the phone would take that large of pictures


Mon Jan 30, 2012 11:07 pm
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Post Re: minarelli 50cc starter clutch clank
What year is your Zuma? My 2008 starter clutch looks totally different! I know because it grenaded last week and I have the parts here in my hand.

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Tue Jan 31, 2012 1:00 am
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Post Re: minarelli 50cc starter clutch clank
well this isnt a zuma motor....its a malaguti f12


Tue Jan 31, 2012 7:31 am
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Post Re: minarelli 50cc starter clutch clank
BlackHornet wrote:
well this isnt a zuma motor....its a malaguti f12


Are you asking someone to explore their minarelli starter clutch to make sure you have yours all back together right ?
If so, I can do that. I'll be in the garage today, you'll see something here late tonight.


Last edited by daex on Tue Jan 31, 2012 7:58 am, edited 1 time in total.



Tue Jan 31, 2012 7:49 am
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Post Re: minarelli 50cc starter clutch clank
haha im pretty sure ive got it back together correctly. the only thing i am confused about is where those two washes go on the top gear. other than that, it should be back together properly which is why i dont understand why the starter sprocket is loose and it clanks when i hit the start button


Tue Jan 31, 2012 7:51 am
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Post Re: minarelli 50cc starter clutch clank
I'll be in the garage today, you'll see something here later tonight. You'll be less confused possibly.


Tue Jan 31, 2012 8:02 am
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Post Re: minarelli 50cc starter clutch clank
As far as the starter gear, one outside and one inside. Get that thing together! :awesome:

Also, it looks like you have a whole new vario.The inner pulley looks bran pankin too. Do you or is it the drive face only?

And the amount of splines should be ok once the nut is tight. Mine doesn't have much showing either.


Tue Jan 31, 2012 9:33 am
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Post Re: minarelli 50cc starter clutch clank
hahaha ya, the vario and drive face a re new.....maybe 20 miles on them. i know that there are enough splines to be secure....i just dont know why the sprocket is so loose back there. i know i put the starter clutch/assembly back together right...but it sounds broke. why is my sprocket so loose???????????????


Tue Jan 31, 2012 10:03 am
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Post Re: minarelli 50cc starter clutch clank
Its loose even with everything fastened and tight?


Tue Jan 31, 2012 10:06 am
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Post Re: minarelli 50cc starter clutch clank
the sprocket? yes. the starter clutch? no


Tue Jan 31, 2012 10:10 am
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Post Re: minarelli 50cc starter clutch clank
I don't see how the big gear behind the vario could be loose if every thing is on and tight? Try installing the spacer that goes the furthest inside, the starter clutch with gear, the VARIO BOSS ONLY and then the drive face, star washer, kickstart gear, fat washer and tighten the nut down and see what you can see.


Tue Jan 31, 2012 10:39 am
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Post Re: minarelli 50cc starter clutch clank
Hello, There is a washer on each side of the small gear.
Here are disassembled, disassembled parts, assembled photos.
Your welcome

Click on to enlarge:
Attachment:
File comment: Back bushing , bearing ring, and spacer in place
2012-01-31_20-40-18_51.jpg
2012-01-31_20-40-18_51.jpg [ 2.13 MiB | Viewed 5367 times ]

Attachment:
File comment: complete disassemble
2012-01-31_20-37-20_606.jpg
2012-01-31_20-37-20_606.jpg [ 1.95 MiB | Viewed 5367 times ]

Attachment:
File comment: all parts layout. as removed - from right to left.
2012-01-31_20-37-04_471.jpg
2012-01-31_20-37-04_471.jpg [ 2.33 MiB | Viewed 5367 times ]

Attachment:
File comment: gear
2012-01-31_20-38-18_242.jpg
2012-01-31_20-38-18_242.jpg [ 2.08 MiB | Viewed 5366 times ]

Attachment:
File comment: clutch x3
2012-01-31_23-07-39_79.jpg
2012-01-31_23-07-39_79.jpg [ 1.81 MiB | Viewed 5365 times ]

Attachment:
File comment: assembled
2012-01-31_20-46-13_210.jpg
2012-01-31_20-46-13_210.jpg [ 2.1 MiB | Viewed 5367 times ]

Attachment:
2012-01-31_23-11-47_43.jpg
2012-01-31_23-11-47_43.jpg [ 2.32 MiB | Viewed 5365 times ]


Tue Jan 31, 2012 8:27 pm
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Post Re: minarelli 50cc starter clutch clank
thanks!!!


Tue Jan 31, 2012 9:55 pm
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Post Re: minarelli 50cc starter clutch clank
Hey guys,

i am sorry to post in an old thread but it fits my problem perfectely.
My starter sprocket (big gear) is loose and wobbles around a lot.
It can move about 2-3mm in direction of the crankshaft.

I assembled it like daex showed so it should be correct. The parts look used but are still in good condition.
Is there something that can be done to prevent wobbling?

If the spacer that holds the starter clutch was a little shorter the starter clutch were closer to the sprocket.
But the contact area is plastic so it might not be wise to get those closer together.


Fri Jun 14, 2013 10:18 pm
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Post Re: minarelli 50cc starter clutch clank
DrProctor wrote:
Hey guys,

i am sorry to post in an old thread but it fits my problem perfectely.
My starter sprocket (big gear) is loose and wobbles around a lot.
It can move about 2-3mm in direction of the crankshaft.

I assembled it like daex showed so it should be correct. The parts look used but are still in good condition.
Is there something that can be done to prevent wobbling?

If the spacer that holds the starter clutch was a little shorter the starter clutch were closer to the sprocket.
But the contact area is plastic so it might not be wise to get those closer together.

I had this problem once. The "clamp" assembly that bolts on with the two bolts wasn't seated properly, and was allowing the gears to wiggle and make a ringing sound when starting. It would still start, but it didnt sound right....
I guess you could check that?

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Sat Jun 15, 2013 2:55 am
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