Torque Settings - Odd Question

Guys, I have a dilema regarding a torque setting on my US Model 1979 A1.
Finally got my Z13 back to her former beauty, but have been through "death of a thousand cuts" sorting my dodgy starter clutch and sub rotor assy, and now have a fully functioning Z13 for the first time in 3 months :woohoo: :woohoo:







My concern is still regarding my Starter Clutch Assy: in that l cannot get up to the specified torque setting of 94 lb/ft without the starter clutch gear (that fits on the end of the crank) nipping up and no longer free wheeling. I am OK upto 86 lb/ft where all works well, but if I increase the torgue setting I loose all free movement on the gear sprocket ??

I've triple checked and all components, spacers & thrust washers are correct and in situ, with no excess wear or play anywhere.

My mate (a time served and savvy engineer) thinks I need to shave a couple of thou off the front face of the gear wheel, to enable me to get upto full torque. To be honest, this worries me a bit, having finally got the bike running. I dont want to introduce more uncertainty.

I understand the torque setting are there for a good reason, but any thoughts on how risky it is to run at this 8% lower torque setting, or would you go for shaving the front face of the gear wheel?

Cheers Tim

Sorry ??, been looking thru my manual, are we talking about the three allen head bolts ? as I haven't pulled mine apart, in the manual it says to tighten them to 28 ft/lbs, or the torsion damper mounting bolt at 51 ft/lbs ? The thing that got me when doing a re-build was getting a torque wrench that measured low inch/lbs accurately for a couple of bolts, had to borrow a mates

Hello Tim:

I too agree with kza:

I do not see any ref. to anything related to 94ft/lbs.

I do see ref. on page 80 to "Install a washer and torsion Damper mounting bolt, and torque the bolt to 7.0kg-m or (51 ft-lbs)."

The three allen sockets on the starter clutch itself get torqued to 3.9kg-m (28 ft-lbs).

Can you provide a ref. out of the manual that indicates a torque setting of 94ft/lbs on that bolt?

On my A-4 I just refurbished my starter clutch (over the winter) and per the book all went as expected.

Your A-1 looks great!

Regards.

Todd.

Todd, KZA hi
Honestly its driving me crazy
In the Service Manual on page 345 it illustrates the Starter Clutch and Sub-Alternator Rotor as fitted to my US model.

My problem is that I have torqued (and sealed) the 3 Starter Clutch Allen Bolts up to the stated 28 ft-lb, but can't get the (left hand thread) Rotor Bolt that holds everything together upto the 94ft-lb (125N-m) specified on page 346 of the manual. Once I get to 86ft-lb the starter clutch gear wheel / cog looses its free wheel.

I cant leave it seized so am having to run at the lower torque setting at present :blink:

Cheers Tim

I wonder if the rotor is not fully seated on the crankshaft?

Are there any abnormal wear marks on the rotor or crank?

T.

If you look on page 38 there is a list of bolts and there torque settings,
It states the Crankshaft torsion damper bolt
10mm 1.25 pitch should be torqued to 51 ft-lbs and refers you to page 80

This is the same bolt that you are referring to.
I would torque it to the lesser setting with a soft thread lock and test it.
Hope this help

Ian