Post by atvsunlspokane on Jul 11, 2014 22:08:55 GMT -5
Now as stated before,your CG200-250 air or watercooled 4 or 5 speed engine may not start. After you do an electricial test and everything tests ok,but you get no spark at the plug, it could be that your Starter Sprague Gear with in your Starter Clutch assembly is bad. Boy thats a mouth full,but anyone can fix this with basic tools.First you disconnect you battery and lay the wires away from the battery. Next remove the2 bolts that are used as your starter mounting. Keep the ground wires together and don't forget to put them back in place when putting it all back together. Now on the left side of the engine,take a thin block of wood and knock your starter out of its housing. Now there is a small round cover that sicks out there. Remove the 3 small bolts and gently pry off the cover,pry next to bolt hole so you don't crack the casing, be gentle, there is no gasket just a rubber o ring. Remove the gear insde and don't loose the small washer there. Make a drawing of which way it comes out. Now remove all the stator cover bolts,look carefully there are a few hidden ones. Lay them out in order. Now using a rubber malet or a screw driver gently ply loose the casing. There is a gasket here,if you tear it just use a small piece of tape to fix or get a new gasket. Becarefull removing the cover for the Stator which is magnetic is on the inside of the cover. Set the cover with wires still conected to the side and tape into place. Now place all the cover bolts back into there holes so as not to loose them or mix them up. Now there is a round wheel type thing right there. You will need to pull it off. Due not pry on it or use a 3 or 5 prone puller,you will mess it up. remove the center bolt on it. This will take some doing,but if you can get an air gun,that is the way to go. If you need to get a rubber type oil filter wrench and a buddy to hold it and use a socket wrench. Now that that bolt is out,you would think it would come off,wrong. To save money simply go to the hardware store and get a 4 inch long 16mm bolt with a 1.5 thread on it for $4. This is the same as the Flywheel puller you would buy online from bikemaster for $12 to $24. Put the bolt in a few threads and place the socket and airgun on it and it will pop right off. If using the other way you will need some musle,but it will work. Save the little moon chaped keyway that falls out,you will need it to re install. Now you are holding the heavy piece and on the back heald in place bu 3 hex head nuts is the Starter sprague gear. Now after installing your new Sprague gear,reinstall going backwards . The keyway is important to get right,have patience. Make sure your large gears are not wiggling back there,and tork down with an air gun or your arm! Place gasket back on casing and gently put stator cover back on.put on bolts and only put about 10lbs of tork or 1/4turn tight. Now reinstall the starter,making sure you seat it into the Stator cover housing and making sure the bolt holes line up smooth. Do not tork on the starter mounting bracket to get in place,it will break. Be sure to hook up your ground wires. Now install the middle starter gearing and replace that cover. Hook up the battery and giv it a start. Total job 2 hours, real easy and quick with basic hand tools and an air gun. If you want you can rent an air gun and small air tank from an equipment rental for a few bucks for 4 hours to do it! Good luck folks, I hope it works for ya. I am doing my second Starter Sprague gear assembly. They are a week spot of the starting system and go out alot or like on my other machine not once so far! Oh yeh drain your oil, refill with 15w40 oil!