I heard marbles rattling in the engine and it just stopped.

[dannylightning]

Originally Posted by tommyjoebilly

I opened up the cover on the left side that exposes the flywheel (?) and the gear on the starter and the starter idle gear which is the go between. This gear had several teeth chipped off. So, I will have to replace that and the starter (bad teeth too!). I still haven't seen what's jamming the engine, so it must be in the transmission. I think I will have to remove the engine from the bike in order to work on that. This is kinda fun, I'm learning as I go. :popcorn:

where did the chipped off teeth get to ?? did you find them, i don't know much about this kind of thing but i would think the teeth could be in there jamming something up if you did not find them.

[BillInGA]

Yikes! That looks ... unpleasant. :sad:

Best of luck. Make sure you get all the little metal bits out before you put everything back together.

[patrick_777]

I guess you found your marble-sound. Yuck.

Take plenty of pics and post the progress up. This could be a learning experience for a lot of folks.

[tommyjoebilly]

In automobiles, the gear on the starter pops out to engage the flywheel. I examined the starter, and it has no such device, so I'm thinking, "Is the starter motor engaged the entire time? That doesn't make sense.". There is something in that encasement on the left side called a "Starter Clutch"? I'm guessing it has some sensor or centrifugal force device that disengages it with the Starter Idler Gear. I'm wondering if that part is what made my starter lose teeth, which in turn made the SIG lose teeth, which put chips into the gears in the tranny, (that lived in the house that Jack built) that led to my bike breaking down. Kind of a "domino effect".
Prior to it "locking up", the starter had made noises like a fork caught in the garbage disposal MANY times. It bothered me, but I thought, "eh, fuggedaboutit". I must check out this part to see if it's functioning properly. I don't want a "sequel".

[tommyjoebilly]

Alright, Patrick. I am now in the process of removing the engine. I tried to turn the engine and it wouldn't budge. Something is jammed in the tranny. I flattened the lock washer on the front sprocket (very nice idea that has a washer with one side bent up against the nut, kinda like how a cotter pin is used on auto wheels, to ensure it won't come loose.) I had to go to AutoZone to rent a 30 mm socket. It's free, btw. I put it on my rachet and got my muscles ready for a fight. My 8 yr. old daughter could have loosened it! The manual says that if you have difficulty, you can loosen the chain tightener on the wheel sprocket. I used ALL of my strength to loosen that bolt, but no deal. I went to buy a breaker bar (a longer "rachet" tool, which doesn't rachet, but gives you some LEVERAGE) and they wanted 32 bucks for a two footer with a half inch drive. Sigh. I thought nah, I'll find a used one on ebay. After thinking about it, I'm just going to push the engine back and that will loosen the chain enough to allow me to remove the sprocket.

[music man]

Wait, did you loosen the axle nut THEN try to turn the adjustment bolt, or did you just try and turn the adjustment bolt?

[tommyjoebilly]

So now, I have to remove the connection between the clutch and your handlebar thingy. I first tried to loosen the splined gear thing, but no go! I took out the cotter pin, but there wasn't enough clearance to remove the pin, so DON'T TRY IT! And the engineers did a REALLY asinine thing in having the bracket containing Philips head screws??? Why????? Philips head screws are the WORST to remove when they are locked up. I got one screw loosened and screwed up the second one. And then Mcguyver spoke to me. "Bend the bracket to release the cable!" So I did! Sucess! :rawk:

[tommyjoebilly]

And the gear shifter assembly, from the thing you use your foot to change gears to the engine. You must disconnect this, obviously to remove the engine. That splined gear thing is SO locked in by corrosion that I don't think it can be taken off, maybe with a gear puller. I'm thinking it's much easier to just loosen both sides of the 'adjustment rod' and take the damn rod out, rather than monkeying around with this nightmare.

[tommyjoebilly]

No, Music, I loosened the adjustment bolt first. The axle bolt looked like Superman himself had tightened it. It was bent outa shape!

[blaine]

Originally Posted by tommyjoebilly

And the gear shifter assembly, from the thing you use your foot to change gears to the engine. You must disconnect this, obviously to remove the engine. That splined gear thing is SO locked in by corrosion that I don't think it can be taken off, maybe with a gear puller. I'm thinking it's much easier to just loosen both sides of the 'adjustment rod' and take the damn rod out, rather than monkeying around with this nightmare.

you need to get gear-shift leaver off the shaft.Remove bolt from leaver spread open with straight screw-driver, leaver will slide off splines.