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  #1 (permalink)  
Old 11-09-2004, 06:35 PM
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Bike Year, Make, Engine: 2004 Special construction
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BDL starter problems

I have a hardcore II with BDL open and a Spike starter. I have engagement about every other try. I am working on a new build where I am using a BDL 2001 drive and aPython starter. This thing is not working at all. Well sometimes. All it does is grind... Then sometimes when it does turn the engine the starter gear will disengage. I have talked with BDL and they pretty much just blew me off. I am pissed off to no end now!! Over 2 grand for thier crap... Any suggestions would be great>.. Thanks!! JOsh
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  #2 (permalink)  
Old 11-09-2004, 08:04 PM
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I just fixed a set up like this. The problem was the starter gear was too far back. The starter gear was far enough back that it rubbed on the rear belt, so it would barely go forward enough to engage the teeth on the clutch shell.
I dont know the brand of starter, but it was a nice lookin one.
What I had to do is dissasemble the starter, Take the starter end that mates to the belt drive system and put it in a lathe and cut it back so that the stater gear was moved forward into the right position.

Don
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  #3 (permalink)  
Old 11-09-2004, 08:41 PM
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HAd same prob Jackshaft sat too far from Clutch basket .
You can View My fix at my thread may have to read a few pages! But it's 100% now.
http://www.clubchopper.com/forums/t1...&pagenumber=39

After all the Mods thought it was wise to order a fresh unit.
Here's a Pic of there new PG-100 Jackshaft . Unable to do a side by side comparison !
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File Type: jpg pg 100.jpg (23.4 KB, 376 views)
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  #4 (permalink)  
Old 11-10-2004, 02:28 AM
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thje 100 is much better i thought i would never fix my problem then i got the new one man what a difference
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  #5 (permalink)  
Old 03-21-2010, 11:19 PM
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Quote:
Originally Posted by RippoDippo View Post
HAd same prob Jackshaft sat too far from Clutch basket .
You can View My fix at my thread may have to read a few pages! But it's 100% now.
http://www.clubchopper.com/forums/t1...&pagenumber=39

After all the Mods thought it was wise to order a fresh unit.
Here's a Pic of there new PG-100 Jackshaft . Unable to do a side by side comparison !
I realize this thread is real old, but does anyone have any idea about how this went all the way through. I tried clicking on his link, and it's dead, probably because it's so old. Here's my problem. I have a BDL belt drive, and this weekend I rode over to a friends house. no problems starting the bike 3 time previously in the day. I needed to run somewhere quick once I reached my friends place, went to start it, and all it did was grind. I took the cover off the end of the starter pinion gear and could see the teeth were completely gone through half the thickness of the gear. Just to get it started I pulled the gear and threw 2 washers behind the pinion gear in front of the spring. then when I put the cover back on I left it loose enough to have about a 1/4" gap, so the jackshaft could throw the gear out far enough. Once I got it started I tightened it back down and rode it home. ( i know most people are asking why I didn't just roll start it and pop the clutch. I can because I have one of those Auto Clutches on it, so it doesn't lock up unless the motor is running, so that's why.) anyway, I guess my question about his post is, "I get shaving some off the end of the gear to push it out farther, but do you have to add some spacers to the side the spring is on, or does the spring compensate for what you take off?? I can't tell.
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  #6 (permalink)  
Old 03-21-2010, 11:30 PM
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If I remember right, have a look at the scooters website or give john a call. They sell a fix for this problem.

http://www.scootersperformance.com/z...a620baa1286308

http://www.custombikebuilding.com/bdl-start-fix.html

"About the Buller Proof Belt Drive Fix
From the Manufacturer

This amazing part will fix the "grind" associated with starting bikes that have a solid or very rigid belt drive actuation. The engineered spring and ramped teeth help integrate the teeth before the unit locks in and turns.

Stop grinding your teeth - and the bike's jackshaft all while producing smoother and quieter starts."


Sorry in advance if I misunderstood
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  #7 (permalink)  
Old 03-22-2010, 09:04 AM
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Thanks. Not looking to buy another part though. I already bought the replacement, just needed the fix for it.
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  #8 (permalink)  
Old 03-22-2010, 06:01 PM
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You might try spacing the coupler so the j/s comes out far enough to fully engage the ring gear.
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