Changing Starter cover and Gasket ,Help please

[Rob1969in]

Hello All,

I received my new starter cover and Gasket today and going to attempt to fit them myself, does anyone have any idea when I can find a guide to doing the job, I'm not a good mechanic so would like to know how difficult it is before I attempt it

[Rob1969in]

Blimey I surprised myself I did it!

It was a nightmare the bearings were stuck and I used the oven and freezer methods ,one of the dowels was ceased in and I had to leave one out, anyone know where I can buy a replacement dowel and also the precise bearings size ?

Anyway the gasket and cover are on and the bike started so I am hoping it's all good!

[DonTZ125]

The dowel 91808-16023-00 can be had at any Yamaha dealership, MSRP $1.48. The bearing is a B6200, available at any bearing house.

I'm not sure I'd recommend running too long with one of the dowels missing ...

[Rob1969in]

what exactly are the dowels for Don? I assumed it was for lining up the gasket? Sorry if I sound a bit thick but I am not mechanically minded at all

[DonTZ125]

The starter clutch cover supports and lines up the gears and bearing for the starter gear train. These have to stay in fairly close mechanical placement, or you can shear teeth off and jam your engine. Replace the dowel soonest.

[Rob1969in]

Sh*t, I didn't realize a dowel would be so important Don, thanks for the advice man,Off comes the fairing etc again then

[DonTZ125]

Bolts can be inaccurate in position due to slop and tolerances in the bolt hole (especially in the cover), bolt OD, thread OD and ID. Dowels are ground to tight tolerances, and the holes are often reamed to equally tight tolerances.

Bolts hold things together; dowels hold them in place.