Not the starter clutch Rebel 450
So I had originally posted on CB's question about a starter clutch issue she was having with her new Rebel 450. Mine was an issue with the starter making a grinding sound when engaged from a cold start.
It was suspect though as it only did it from a cold start and not when the engine was warm or when the kill switch was in the off position. So I pulled the starter and checked it out; it was a little dirty around the brushes, but all looked good around the bearings with no excessive play.
A little tip if you do take your starter apart and it has the 4 brushes around the commutator, these are difficult to get back into place without 4 hands. I used small plastic ties about 4" long and tied each one around the brushes and just snugged them up loose. I was able to slip the commutator back into place easily and then individually removed the ties and everything was golden. I did a flush of the engine with 3 litres of Varsol overnight thinking there was a starter clutch issue, since the starter looked good and then a complete oil change and new filter. Still no joy as the sound was still there.
I did check the balancer shaft aduster when I got the bike and noticed it was at the end of its adjustment. There is a procedure to remove the clutch case in the FSM and move the adjuster over a few teeth to gain more adjustment. When I removed the clutch case I noticed the chain for the balancer shaft was quite loose and it comes very close to the upper motor case in a few spots. I did the adjustment to the adjustor by moving it two teeth over on its shaft and adjusted the chain tight.
Put everything back together and no more starter noises, so it was the balancer shaft chain hitting the case when started from cold. I can only guess when it was warm there was less slack and it didn't do it. This was an interesting excercise as I assumed that is was a starter issue and possibly the starter clutch and it turned out to be something entirely different. The motor was quiet I thought before the adjustment, but after it was quite a bit quieter. If you have a Rebel 450 and have never checked the balancer shaft chain adjustment, there is a removable plug in the upper right portion of the clutch case. It would be worth checking to see if you have any adjustment left on the adjustor and making the adjustment if you do.
"Common Sense" .... really isn't that common!
1976 CB 400 Four -1976 GL1000 Goldwing
1982 CB 900 Custom- 1983 CB 1000 Custom
1983 CX650E EuroSport
1984 GL 1200 Goldwing Standard