starter motor / exhaust manifold

S

shank

Location
australia
Hi,

I have a DASA motor and b pipe exhaust. The starter motor is not cranking everytime. Sometimes it is just making a whirring sound without cranking the engine over.

I was gonna take off the starter and have a look but i cannot work out how to get the exhaust manifold off to get to it. I cant get a spanner on the two bolts in the top center of the exhaust manifold underneath the power valves. I cant take the power valves off as the manifold is in the way. And i cant get a spanner on the bolts on the manifold. I have taken the power valve covers off and have more room but still cant spanner turn the bolts.

Anyone know how to get the exhaust manifold off ?

I have attached pictures

Here is with the powervalve covers on. You can see the bolt at the top of exhaust manifold going into block

exhaust1.jpg


Here is with the covers off. More room to access bolt but cant get spanner on it. Cant putt the power valve plate off as it hits the exhaust manifold when trying to remove

exhaust2.jpg

Here is a top down view of it.

exhaust3.jpg
 
Mdavies_02

Mdavies_02

Location
Stouffville, Ontario
I would look up how to modify a 12mm Crescent wrench to get more access on your FP Exhaust Manifold bolts. A little bit of grinding material away on the wrench goes a long way. That said, I've never had power valves so I don't know how to handle that.

In regards to your starter issue I believe you are having an issue with your Bendix not engaging your flywheel. I would remove your flywheel cover, pull your flywheel, and investigate the bendix. Sometimes soaking in ATF for afew days can bring them back to life, however if it doesn't JM Sells USED OEM bendixs for $60 and I always have one as a spare as it is a common issue.

If you find water in your flywheel compartment I would replace the gasket as well as pulling your starter and reinstalling with a thick bead of 1211 around the neck where it meets the cases.

Good luck

Mike
 
Wizards Powersports

Wizards Powersports

Location
Denver, NC
Agreed, you probably have a bendix issue. I have clean, inspected OEM ones for $30 shipped. Also, if you end up having a starter issue, they can be removed without having to pull the exhaust manifold.
 
S

shank

Location
australia
I am located in Australia though.

I will try pulling off the flywheel cover etc.

I got an 800 SXR lying around will the kawi starter / bendix fit the starter on the DASA. I would assume it is running yamaha parts.

I dont have either parts off at the moment to compare.
 
S

shank

Location
australia
Tried grinding two wrenches down. Have to make them so thin they bent when trying to undo bolt. So that didnt work.

I gave up and pulled fly wheel cover off.

Wouldnt ya know it bendix was working and pulled bendix off and startor was spinning every time. Tried on and off for 5 mins. So it works when i test it but was intermittent not working before. I hate it when things do that. I gonna try again later.
 
S

shank

Location
australia
Ok i was able to replicate the issue last night. The bendix is popping out and engaging the flywheel. But is not cranking. It is sitting there making a whirring noise and not spinning flywheel. If i pull bendix off it seemt to turn freely. If i run starter without bendix attached it spins every time. Either starter is not got enought torque everytime to spin flywheel or bendix is getting stuck. Have not been able to get to starter motor to get it off yet and have a look.
 
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