JCL MP 250 A starter clutch replacement By 4950cycle (Read 7,634 times)

[4950cycle]

Hi, My name is John. I'm a noob here from north central FL. and thought I'd come here to post dealing with a broken starter clutch on my girlfriend's 2007 JCL MP 250 A. The other day my girlfriend went to start her scoot when all it did was make a whiring sound (starter motor freewheeling) instead of turning the engine over to start it. After I talked to Jeff at Mudville Scooter & small engine repair outside of Idianapolis ID. and told him what the scoot was doing he said he believes it to be the starter clutch. And he proceeded to tell me the best way to go about replacing it. After studying the design of the Yamaha YP 250 on the PDF files right here on Scooter Professor and realizing a scooter starter does not do its job quite like a car starter does its job. It is a direct drive with a ratcheting action (slips going one way and catches and turns the motor over going the other). I agreed with Jeffs conclusion and proceeded to start peeling off the layers of plastic that a water cooled scooter is buried in. Pulled the starter out and inspected its drive just to make sure it wasn't a part I could just bolt on. Instead of doing this medium difficulty operation I know for sure now I have to do . I have it all opened up now and will try to get some pics up so you can get a visual on what I am speaking about.

[alleyoop]

Yes that is the way the Starter Clutch works and it will look like this.
Alleyoop

[4950cycle]

Thank you for the pic Ally. This is not a pic of a JCL MP 250 A or Yamaha's YP 250 motor. It looks like it may be a GY6 150 motor. But for all practical purposes it is a very close picture discription of what I am looking at in the 250 Yamy style 250 motor. So close I won't post a pic . Again, Thank you

[bobf]

Why not edit your post and remove the attachment that you did not put there. Or can't you do that?
.

[alleyoop]

4950Cycle,
Yes the picture I put up is of my GY6 motor but they all are pretty much sameo sameo I just put it up so you would have an idea of what to expect. And by all means Take pictures of yours and post them so other 250 folks will know just what they are getting into.

Then JR will put all your pictures in the 250 tech section for others to know how-to if need be. As they say Pictures Are Better Than A thousand Words.
Alleyoop

[4950cycle]

When I go to modify the post the attachment is not there to remove bobf ?

[4950cycle]

If I had a replacement gasket I would be a little happier. This things got to hold oil and not leak when I'm done. A little warning to scoot dawgs that will be doing this repair. Watch buying the starter clutch on Ebay. there are a couple sellers that sell starter clutches that have no idea what their selling. The starter clutch they are trying to peddle as a Linhai 250 starter clutch has 57 teeth when a JCL MP 250 A Linhai 257cc engine takes a 49 teeth starter clutch with a center hole thats about 24mm or Juuust under an inch. And they will blame it on you when it will not work what so ever for you. And yes I will post pics tomorrow Ally if I get a chance. Thanks for the help.

[alleyoop]

ALL FIXED,
What I did is I deleted that post and just copied what was in the post with the attachment to his following post that said NOT TO CLICK on the attachment
Alleyoop

[4950cycle]

Sorry about the picture delay. This is what I get for not knowing how to do it myself I'm way to busy to learn anything lol Have to depend on the girlfriend and getting a bachelors degree at 50 aint easy. So shes been darn busy. Anyway, Nuff of the excuses. Finally bought a $60 to my door replacment starter clutch off Ebay. The guy had the right picture with the right word discriptions + meassurments. So Even though the other ebayers were clowns I figured it was worth a try with this guy. At least he (the seller) had enough sense to know giving meassurments was important. The other sellers with thier starter clutches could care less if you got the correct part from them. Knowing that I bet 60% or more of people won't be bothered with shipping it back when its incorrect. Pics tomorrow if I have anything to do with it.

[4950cycle]

Heres the JCL MP 250 A stripped down with exhaust and hose and ten 8mm case bolts taken off. Ready to remove the side case. This is the Linhai 257cc

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[4950cycle]

Here is pic of the Linhai 257cc with the side case popped off after all ten 8 mm bolts, exhaust and such removed. Exposing the Stater,flywheel, and starter clutch (bolted to back of flywheel) PS Stater is in the cover and you can't see them in this pic.

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[4950cycle]

Heres a pic of a little more detail of the starter gear system. The starter is still bolted on with the red power cable going to it. Its engauging the gray gear at the upper,middle left. Then gray gear engauging the starter clutch gear (large metal gear). This is what turns the engine over when you hit the starter button ( if starter clutch engauges ) Mine is not working properly and not engauging the engine.

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[4950cycle]

The nut that holds the flywheel on is about 24 mm. I didn't have a metric socket this big. But I did have a 15/16 socket that fit real nice and worked with the impact wrench (don't think I needed it). Pull the timing chain cover off (same cover you take off to time the valves for a valve adjustment) and keep the motor from turning over by sticking a screw driver in the cam chain and sprocket. Mark the three allen bolt holes with a perminant marker in the fly wheel. You will want to use the same three holes to bolt the flywheel back on after you put the new starter clutch on so it will still be balanced. This may not be totally neccessary. But I'm kind of anal about balance. Now take the three allen bolts out and pull the flywheel. Now slip the starter clutch off. It should slip right off after removing the flywheel and key from the keyway. I was advised by Jeff at Mudville Scooter and small engine repair to pull the flywheel with starter clutch still attached. But when I did it this way the key interfeared with the starter clutch comeing off after the flywheel. So I will change this proceedure by unbolting the flywheel from the starter clutch first before removal as already stated.

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[4950cycle]

Here is the starter clutch with gear. I will put a pic of the flywheel in a vice while I remove the three allen bolts that secure this starter clutch to the flywheel. At this time I am waiting for a new starter clutch to reinstall to correct the problem. They say it will arrive via UPS or fedex by next thursday. Today being Sunday.

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[4950cycle]

Well, Like most Chinese dealings everything got botched up and it took them 3 or 4 days just to realize they didn't have a starter clutch in stock in the US. for the Linhia 250 (257cc). Said it would be about 25 days or so. So I canceled order and found one in stock at Absolutelyscooters. Cost me $20 more but I have to get this thing back together before I totally forget how everything goes. So, The parts total is up to $80 for the starter clutch,and $18 for a gasket kit I found for this motor. So $98 in parts to my door. The flywheel cover (covers starter clutch also) gasket didn't do well comeing off. So instead of having a leaky engine I thought it might be worth the $18 extra to get a professional result when I'm done.