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Discussion Starter #1
Just changed friction plates on my 2004 VStar 1100 Silverado. All came apart smoothly as well as re-assembly, making sure everything was installed in the correct direction and order. Went to start it and the starter is acting like it is binding and getting very warm. Won’t spin over enough to start the bike? I just rode it 150 Miles just hours before with no starter issues. Problem only presented itself after changing the friction plates. Could this be an adjustment issue? With bike in neutral it rolls freely and wouldn’t think there would be any resistance on the starter? And ideas?
 

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Super Moderator "Loose Nut"
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If it's rolling in neutral without drag the adjustment should be close. Check the battery and cables. With a meter should be 12.4 or higher. If it drops to 10 or less when you engage the starter, the battery went south. If battery test good, check both ends of both cables for tightest and corrosion. It doesn't take much for full power not to go thru. Keep us posted.
 

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try rolling the bike in 2nd gear with the clutch pulled in - it should be harder than duckwalking it in neutral, but unless the clutch is stuck you should be able to.

BTW, don't push it backwards in gear - you don't want the timing chain spinning in the wrong direction.
 

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Discussion Starter #4
I’ll check the battery and cables again. Just put the old clutch friction plates back in to see if the problem changed and it didn’t. Seems odd that there would be a battery issue when I was just ridding it and all I did was change the clutch disks. Also tried jump starting it off a battery box and nothing. Starter is hot as hell too.
 

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check the starter clutch assembly might be stuck.
 

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If the starter is having trouble spinning the engine over, it might be a good idea to take off the quarter size cover on the crankshaft (its on the left side on my 650) that you use to rotate the engine to adjust the valves, put a wrench on the crankshaft and make sure it turns normally.

Only turn it clockwise (on the left side of the bike) because Vstar motors spin backwards (the opposite direction as the front wheel) and you don't want the timing chain to go slack from spinning it backwards.

The engine should turn over easily with one hand on a 3/8" ratchet drive, until you hit the compression stroke on one piston or the other. Its possible you got something messed up in the clutch assembly and its dragging the engine down.
 

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Discussion Starter #7
Follow up... This is ugly kids, so shield your eyes while reading this. When installing the engine case cover after the clutch replacement I misplaced a longer bolt where a shorter bolt should have been installed, directly over the forward facing cam gear. The bolt was tightened enough to drag and gouge the cam gear all the way around while not allowing the engine to turn over fast enough to start. Corrected the error and installed the correct length bolts. Bike fires right up, clutch works like a champ but there is a severe vibration and whirling sound in the motor. Upon inspection tonight, I have found 2 broken teeth on the cam gear that apparently struck the bolt rubbing the cam gear. Never been so disgusted with myself to say the least. Ow does anyone know if the cam gear cam be removed with the engine in the bike or without complete motor disassembly?
 

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Super Moderator "Loose Nut"
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That's a real bummer. Unfortunately I can not answer your gear guestion. Hopefully someone else will chime in. Please keep us informed on the fix.
 

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that's rough - I always worry when taking out bolts that are different sizes, and there are several assemblies like that on these bikes. You are not the first guy to get bolts in the wrong place.

The photos seem to show only part of the teeth chipped off. If the gears are still meshing Im not sure where the whirling sound or vibration would be coming from. Its possible the bolt put a heavy thrust load on the bearings on that gear and messed up the bearings on that gear shaft. It doesn't take much end play for things to start sliding against each other that are not suppose to be touching.
 
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