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Old November 21st, 2017, 04:34 AM   #51
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Guys, the milk in the sight glass is no cause for concern. I had this issue a couple years ago during the winter. Someone suggested leaving the oil plug off after you get it up to temp and park it, which worked after a few cycles - just remember to put your plug back in (I rested mine on the ignition bezel so I wouldn't forget and lose it).

Now, if your engine physically can't get up to working temp, can't help ya.
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Old November 21st, 2017, 05:58 AM   #52
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I second no cause for concern. However if that doesn't satisfy you, you might try a piece of cardboard over half the radiator. That'll get it up to temp better when riding in cold weather.
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Old November 12th, 2018, 08:50 AM   #53
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So, discovered a little hiccup with this DIY. There's a guide pin that holds the drive gear between the starter spline and large generator gear wheel. This pin stayed attached to the generator cover when I pulled it off. When I went to reinstall cover after starter swap, heard the tell-tale sound of a metal part *ding* as it hit the bottom of the generator housing. Found a ring spacer that I deduced goes behind the drive gear that the pin should have held in place.

Here's where it gets really nasty...
1. Discovered after this discovery that the guide pin is removable and should have stayed in place, holding the drive gear in tact. ***If you do this DIY and the guide pin stays attached to generator cover, remove immediately and seat through drive gear assembly. It free floats so it will break free by hand.
2. When trying to fish the spacer out, it fell into a 1/4" x 3/4" scavenge port (on bottom right when looking through the gear) that drops into the lower sump. Ruh-Roh.

I didn't have a magnetic fishing tool handy but my initial recon says it looked aluminum anyway. I pulled the oil screen filter plugs but not likely it would enter that section based on small cored passages leading to this scavenge area.

I'm working out of a parking lot with adequate tools but can't pull the engine or crack the entire case. I just finished the clutch mod and would rather not re-crack that case.

So, am I fooked? If I took the bike to a shop (in Southern Italy, mind you), they'd laugh at me and charge me a fortune for all the other half-finished projects I have going.

Can't touch the bike for a week so all input welcome. Items 8 & 9 are what I'm referencing.

https://drive.google.com/open?id=12G...80w2XjrRBdsWgH

Last edited by gatdammit; November 12th, 2018 at 09:26 AM.
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Old November 12th, 2018, 01:30 PM   #54
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So when you pulled off the generator cover, it pulled the shaft, gear, and spacer out as one unit?

For some reason I don't feel like the spacer should be made of aluminum. I would first try buying a magnetic tool (it's good to have around anyway) and stick it in there. Also try going in from the drain plug since it should have settled at the bottom directly beneath where it fell in the hole.

Realistically it should not cause any damage because there are oil screens but for peace of mind I wouldn't want it floating around in there either. Will try to offer suggestions if I think of anything.
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Old November 12th, 2018, 01:32 PM   #55
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Can you see into the sump when you remove the oil screen?
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Old November 12th, 2018, 01:34 PM   #56
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Can't tell what material it is based on this pic... it might be worth buying one for $9 to see if the magnet option is worth investigating.


Last edited by kuksul08; November 12th, 2018 at 01:38 PM.
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Old November 12th, 2018, 03:38 PM   #57
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Thanks Kuk.

When I pulled the cover, all the gears stayed put but the centering/ guide pin stayed with the outer cover. Just a heads up to re-insert back into gears immediately.

I have a couple magnetic wands, just misplaced or lost at the moment. I drop hardware all the time and usually have these by my side.

I will definitely order another. When I looked in the oil drain section, only saw screens and a narrow scavenge port that just barely would fit the spacer.
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