Final call for help with my no crank condition
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I’ve been on this forum before trying to fix up my hyosung that was given as a gift and after months of work $1000 into it many hours of research and finding parts I finally got this bike up and running it used to be just a frame with bundled up wires going everywhere and I managed to actually put this thing back together and get it running shifting breaking everything one week ago today the bike fell in my backyard. I don’t know for how long it was on the ground. I had assume it was for some hours because the left side of the engine was completely caked in oil, oil came up and out of the intake boots and flooded the entire starter clutch cavity. Now the bike will not crank. I have all new wires all new solenoid on new starter zero resistance so I decided that it’s not electrical. Since the entire system works and engages the start so I thoughtIt has to be somehow mechanical so I opened up the starter clutch case and everything looked pristine inside like it’s never even been opened, I spin the flywheel and it only spins one way and not the other I also move the idle gear that is connected to the flywheel and that one moves one way and not the other, which let me know that the one way clutch is working, but when I put the starter in, not only, is it a struggle to get in there, practically forcing you to jam it in there when it was never like that before once you have it in none of the gears move and I’m thinking maybe it’s supposed to not move once everything’s together that can make sense from a mechanical standpoint but when I add 12, 13 or even 15 V to the starter the gears instantly jam up and does not turn the engine over. It’s like the starter or maybe the idle gear is misaligned by a hair and is causing too much load on the starter I also took the starter apart and completely cleaned it thinking that it got flooded in oil and even checked if it was perfectly straight, and so it was clean and perfectly straight and when I put it back together, it spins even faster and more powerful now I live in Rhode Island it’s getting too cold over hereand I put too much time and work on this bike on this bike for it to be taken out by one stationary fall in my backyard on grass. So I am willing to work on it. in the hopes of figuring this out. but as it stands now, I am completely stumped It’s why I’m asking for some help one last time, but as it stands, it might have to get sold I don’t want to cell, but I just don’t know how to continueif anybody can help me I would greatly appreciate it. Thank you
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Sorry to hear that after all the effort , a fall forces you back to the garage to sort it out again! Hopefully its nothing major, forgive me for asking a series of questions , but i will be targeting the crank itself now.
1. Can you spin the flywheel by hand and if you do, do you hear any hiss sounds as thepistons move up and down ?
2. Oil was coming out of the intake rubber pipes ? what do you mean? Not unless the “engine overflow” pipe is connected to the airbox rather than overflowing itself down to the road surface (like most hyosungs do) i know EFI models have their engine outlets / breathers go all in to the airbox.
3. If you had a friend or family member with you , sit on the bike, let them push you down the street and you shift to 2nd gear or 3rd gear , will it bump start at ? (we are bypassing the starter motor to verify the engine doesn’t lockup by itself) ,excercise caution though , it may jerk and shoot forward hard , so being cold and icy , the road conditions may be unsafe for sudden tail spins or braking. Just be wise!The key here is making the crank fully spins by hand when you rotate the flywheel manually in both directions. Just to confirm nothing got misaligned when the impact / shock of the bike falling caused something to rattle (it shouldn’t since it just fell in the grass than a jagged concrete surface, i would be more likely to loose my clutch casing or stator casing if it fell hard on to a sharp rock/boulder)
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Yes actually i was able to spin the flywheel with my hand and it spun clockwise from the perspective of the starter clutch assembly pretty easily almost with 0 resistance and i wasnt listening for the hiss of the pistons but i didnt hear anything either i dont know how audible its supposed to be but that fact alone might answer your quesion since i didnt even catch the sound by mistake. Also What i said about by oil coming out of the intake pipes that was A mistake I am not 100% sure of where the oil came from but all I know is that the entire side of the engine was coated in oil and it makes it very difficult to see where the origin was from sorry, my mistake, lastly I did not try bump starting it, a very good idea could definitely tell me a lot right now I’m heavily leaning towards the idle gear and the starters pinion not sitting together correctly and causing a jam because when the starter is in the bike, I could not turn the flywheel either direction. It would stop all movement but after I try a bump start, I’ll update with the results thank you for the advice
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I’m thinking there might be a semi Hydro lock or at least some liquids in the chamber, not allowing the starter to fully rotate the engine because it was on its side outside for a couple of hours by the time I went outside and saw it there there was a pool of oil and you know how oil loves to get trapped in the most annoying places so next chance I have I’m gonna try to turn the crankshaft bolt. See what I feel.
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God forbid , well on a carb motor, that’s got damaged carbs (burst floats etc) and it would mean the oil stinks heavily of fuel when drained and comes out like black water , could be another tale-telle sign .
Injected bikes not so much as injectors stay shut when the bike is OFF , as does the electric pump
Although i would not discount the likelyness of Coolant (Radiator Anti Freeze) or Oil making its way to places it should not (expect a creamy looking oil! – God forbid)
You’re on to something there…. Just hope its nothing minor
It sounds stupid, if the bike’s stator casing was hit hard and didn’t break, check inside to make sure the holes where the idler shaft sits is not bent in anyway causing the idler gear to skew a little bit instead of staying purely straight. Spirit levels can be handy if done right!
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