mz500 sprague clutch starter .. a how to

Vehicles equipped with the 500 cc Rotax engine

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mz500 sprague clutch starter .. a how to

Postby hmmmnz » Thu Jan 14, 2010 9:48 pm

tools needed.

allen keys, 24 and 27mm sockets or spanners, 13mm socket/spanner, a couple of small screw drivers, circlip pliers (or screw drivers again),

ok
1. remover the cam belt cover
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2. remove the starter gear cover
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3. put the bike at top dead center and lock in the crank,
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make sure its locked in position with your 24/27mm socket before you go any further,

4. as per belt change, remove all the adjusters and belt,
remove the top and bottom sprockets, making sure everything is marked

5. remove the back cam belt plate

6. remove the kickstarter and the gear changer
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7. remove the washer and the little clip behind it
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8. now its time to remove the clutch cover
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9. with the clutch cover now off, you just have to unbolt the gear that is ontop of the sprag
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10. remove the snap ring, and then use a flat bladed screwdriver to squeeze the circlip on the sprag (this releases the sprag) (red arrows)
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11. pull the sprag free
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bugger that looks shagged, :D
either fix the spring (shorten it) or replace the sprag completly
it should look like this
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put the new/fixed on in place and reverse the whole procedure,

fun times

it took me about 2 hours, having never done it before, and not really having any real instruction,
i think i could get that down to about 40mins
"Don't... Don't put the noodles and the dumplings together in the boat. They'll fight! The noodles are bullies. Poor dumplings."
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Re: mz500 sprague clutch starter .. a how to

Postby iceman » Thu Jan 14, 2010 10:02 pm

Nice job !
On an Aprilia V 990 Rotax motor you have to pull the flywheel and all day affair and the parts alone are about $400/$500 lucky they don't go often. :-D
You're just left with yourself all the time, whatever you do anyway. You've got to get down to your own God in your own temple. It's all down to you, mate.
John Lennon
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Re: mz500 sprague clutch starter .. a how to

Postby hmmmnz » Thu Jan 14, 2010 10:50 pm

yeah most yamaha's with sprag clutch starters are like that as well, along with the cagiva singles as well,
the ducati's and all the rotax based lumps (aprilla, bmw ect) are like the mz

oh and in case you were wondering, the ktm lc4 sprag is the same, and pant loads cheaper,

9 times out of 10, its just the spring that has streched, and the lobes are normally still in good condition
its very easy to shorten the spring and get alot more life out of the sprag..

i can do a write up of that with pics if any one wants it
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Re: mz500 sprague clutch starter .. a how to

Postby comanche91 » Fri Jan 15, 2010 12:11 am

Great DIY - thanks hmmmnz. Love to see your spring writeup too. But all this good stuff belongs in the not-created-yet MZ500 forum. I have a few I'd like to contribute also. :-D
-Don
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1-3/4 1995 Silver Stars
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Re: mz500 sprague clutch starter .. a how to

Postby hmmmnz » Fri Jan 15, 2010 1:20 am

yeah ill do a wee write up on the sprag clutch fix,
i might do a fork seal post as well, as i blew one of my fork seals last week....
mustn't do jumps on mz its not a dirt bike :D

it did pretty well off road, despite its weight, although it was pretty hard going in the sand,
funnily enough, i was beating a mate on his sx450 (ktm) the 4 speed box on his bike limited his top speed
so anything above 80kmh i left him behind.. much to his disgust hehe
"Don't... Don't put the noodles and the dumplings together in the boat. They'll fight! The noodles are bullies. Poor dumplings."
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Re: mz500 sprague clutch starter .. a how to

Postby Nozz » Fri Jan 22, 2010 12:00 am

I think I may have this same problem. Thanks for posting this. Did your bike clang and bang and not want to engage when you push the starter? I am having that problem now...
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Re: mz500 sprague clutch starter .. a how to

Postby hmmmnz » Fri Jan 22, 2010 3:51 pm

yeah it used to make the evilist metalic clangs and bangs,
it really sounded like the bike was going to tear ittself to pieces :D
9 times out of 10 you can repair the sprag (i did another write up on how to repair your old one)
you'll get heaps more life out of it yet :D
"Don't... Don't put the noodles and the dumplings together in the boat. They'll fight! The noodles are bullies. Poor dumplings."
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