Hi guys, I need to tap into your collective knowledge.
I had to rebuild my engine recently after the sump plug fell out. Don't even ask how that happened. Anyway, question is when turning the engine by hand using the generator bolt, should the starter turn also? Cos mine does now and I dont remember if it did before. It greatly adds to the resistance when turning. When I was putting the main starter gear with sprag bearings etc back on the generator I noticed it locked up one way and turned the other but not freely as I thought it should. I haven't fired the engine up yet, and don't want to incase the engine really is locked to the starter gears and it burns the starter up.

Any thoughts?!

AFAIK, engagement should only occur in one direction, and it isn't that one.

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Pat- 2007 DL650A was ridden to all 48 contiguous states. 2012 DL650A is just getting started.
Nicknames for posting ease on my part, Vee = all DL1000s. Wee = 2004-2011 DL650s. Glee = 2012+ DL650s

I don't have one in front of me to look at, but I am thinking that if you turn the generator bolt clockwise ( like when tightening ) that is opposite of how it turns when the engine is running. That would engage the one-way clutch and cause the starter to turn...I think. Been a while since I have been in there.

Does the starter turn if you turn the generator ( rotor ) in the opposite direction? If not, you may be ok. I don't remember if the starter gear/one way clutch can be installed backwards or not.

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'12 DL 650- '04 DL 650- '03 DL 1000- '04 R 1150 RT

WERKS modified clutch baskets for DL and SV 1000's.
The BEST in chudder control, noise control, and lasting durability! AVAILABLE HERE: www.werksparts.com
Want straightforward easy to understand answers to clutch basket questions or concerns? E-mail Terry info@werksparts.com

Starter rotates whether I turn engine CW or CCW by hand
At this point I guess it makes most sense to remove rotor again and check everything. Starter turns engine as it should (turned engine over w/o plugs to check oil pressure) but it seems to be engaged all the time. I'm thinking I re-assembled the sprag clutch wrong somehow. Or maybe its damaged?

Don't turn the engine clockwise, CC only.

__________________
Pat- 2007 DL650A was ridden to all 48 contiguous states. 2012 DL650A is just getting started.
Nicknames for posting ease on my part, Vee = all DL1000s. Wee = 2004-2011 DL650s. Glee = 2012+ DL650s

Sounds like you better take the rotor off and look at the starter clutch/gear carefully. Possibly just not seated right on the back of the rotor which could bind it enough so the clutch won't release.

__________________
'12 DL 650- '04 DL 650- '03 DL 1000- '04 R 1150 RT

WERKS modified clutch baskets for DL and SV 1000's.
The BEST in chudder control, noise control, and lasting durability! AVAILABLE HERE: www.werksparts.com
Want straightforward easy to understand answers to clutch basket questions or concerns? E-mail Terry info@werksparts.com