What Did I do????????

cipher5791

cipher5791

Registered
I was in the garage today finishing up the install on my TI Force Full Exhaust system. I began to fire up the bike to hear what she sounded like. I started the bike last night and she started up just fine. I had trouble starting her after the install. I kept trying for at least five or six times and then I hear a pop. I hit the starter again and I heard a funny sound.:banghead:

I look at the cover where the starter is an I noticed a crack.:banghead:
I began taking the cover off and I found this.
What have I done and what will it take to get her back running?
Here are some pics. Somebody please help me.:please:

SD530432.jpg


SD530433.jpg


SD530430.jpg


SD530431.jpg
 
What year bike??

The later models had a beefed up starter to prevent damage in case of a kickback. Not sure if that would have helped, but it sounds like what has happened
 
looks like a Gen 1 busa.

I suspect you didn't have the case saver ti ring that goes around the starter pin support hole on the case. It looks like upper case damage but the pics are a little fuzzy so I wouldn't want to pass judgment. How much of the pin support is damaged.
 
Commuta_Busa said:
looks like a Gen 1 busa.

I suspect you didn't have the case saver ti ring that goes around the starter pin support hole on the case. It looks like upper case damage but the pics are a little fuzzy so I wouldn't want to pass judgment. How much of the pin support is damaged.
Click to expand...



2002
The pin support broke in half. I think it is due to spin back. I have never had this kind of trouble geeting the bike to start. Did I have the header bolts too loose? Am I looking at replacing the upper case?:please:
 
The two ways I know to resolve this is to either replace the upper case or have someone weld a new support and drill it for the pin. The welding needs to be done by a pro. The pin support is critical. There's another way I know but it requires a custom machined piece which is not cheap. I wish I had better news for you. Perhaps someone else has repaired this a different way.

cipher5791 said:
2002
The pin support broke in half. I think it is due to spin back. I have never had this kind of trouble geeting the bike to start. Did I have the header bolts too loose? Am I looking at replacing the upper case?:please:
Click to expand...
 
I had a kickback last year but luckily it only killed the igntion/starter cover because of the Ti ring.

P4115673.jpg


P4115680.jpg
 
yup, your pic clearly shows that the starter pin support which is part of the cast of the upper case is broken.

Look at the second pic I posted you'll notice there's a ring/sleeve around that support to give it additional strength and avoid the support from breaking.
 
Hope it goes better for you cipher, I'm wanting to see the exhaust. All good things in all good time...
Good luck with it bro.
 
Dumb question: what would cause "spin back" or "kick back" to occur?
That damage looks serious. I hope you get it all sorted out as cost effectively as possibe!
 
Sorry to hear about your bad luck. Keep us posted on how the repair goes. Can't wait to hear the new exhaust!
 
CCbusa05 said:
Dumb question: what would cause "spin back" or "kick back" to occur?
That damage looks serious. I hope you get it all sorted out as cost effectively as possibe!
Click to expand...

Ther is no such thing as a dumb question. I wish i had an answer to your question as i would like to know how something like that happens.
 
CCbusa05 said:
Dumb question: what would cause "spin back" or "kick back" to occur?
That damage looks serious. I hope you get it all sorted out as cost effectively as possibe!
Click to expand...

Too advanced. The engine wants to spin in the opposite direction you have the advance too soon when the piston is on the rise, not closer to TDC (top dead center).

Even if the thing spun back, the starter clutch is a one way direction device. If it spit back, it freewheels backwards, but locks the other way.

What happens is the gear tooth gets in between the gears, spreads until something gives. What parts cracked looks like they can be replaced with starter type outer and inner covers. But what I question for a new case is if that boss where the shaft goes is wobbly you install to find out. If that hole was pushed open by the spread of the one section of gear tooth, the boss elongates as part of the spread damage, then a case is needed. Other than starter housing being multi-piece, the starter shaft boss is part of the inner cover, you are home free of swapping out a set of engine cases. Find more broken teeth in the sump pan area. Especially that tooth that caused the covers to crack apart.
 
a weak battery can cause this king of carnage. Also if you let go of the start button before the engine starts on it's own can cause this. The older Gen 1 busa start gears were susceptible to this. 03 had a change to the start gear assembly.
 
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