620 HELP

[ChiefH134]

Did  a major overhaul on the 04 620 this weekend to freshen up my "gas saver". short List: 2002 600 dark clutch with Barnet plates and springs swapped in place of Adler slip clutch, lightened flywheel, rick stator, new regulator, pod filters, and power commander.  obviously tires, oil, filter , belts, etc.

Now the problem, after spending a whole day fighting the flywheel nut off finally was successful (dremmeled cut it off) got everything re-assembled filled with oil tried to fire up what I expected to be a face melting fun roar. AND nothing just click. tried again smelled smoke immediately removed the key and turned off the kill switch, Never found anything melted but the starter was awful hot. So assuming the motor was just bound up I put it in gear and rocked back and forth but cannot get the motor to turn over.

At this point I have no idea what could have gone wrong, I guess start on the flywheel side and hope to find something amiss while re disassembling?

Help Please 

[thorn14]

Did you use a penny in the gears or anything else to help you install the flywheel? Starter sprague clutch going the right direction?

[ChiefH134]

we used an air impact to remove the nut and when we spun it off at one point the starter gear sucked in a rag.

[thorn14]

Rocking it back and forth, does the engine move freely? Try with spark plugs off and in 6th gear spinning by hand while the rear is in the air.

When you hit the button to start, do you get the starter spinning, or just the click of I assume the starter solenoid?

Look up starter sprague clutch being installed the wrong way and maybe there is a easy way to check without breaking everything apart as that is a piece you touched on install.

I haven't experienced this issue so I'm guessing based on my own flywheel swap experiences (twice now).

[ChiefH134]

tried all that decided the case needed to come back off. Found the nut supplied by sling shot racing was too large outside diameter, it has now gouged the inside of my brand new stator and was locking the motor together possibly fried my stator.  never using their product again!!!!!!!

[ChiefH134]

Stator inside diameter 41.5mm supplied nuts by slingshot racing 43.6

[Speeddog]

How did you manage to get the sidecover on?

[ChiefH134]

it pushed on normally and didn't seem any harder to seat and tighten then I would expect. Apparently it should go on a lot easier as we were forcing the corners of the nuts into the stator. Figured if I needed the puller to get the case off it was no surprise to tighten the case down with case bolts.

[thorn14]

Had that same problem with their nuts except my cover wouldn't even go on all the way before hitting. You got lucky enough to slip right through. I just reused the stock nut even though it's not the preferred method.

[ChiefH134]

I know it has been a few months but I did eventually get the proper sized nuts from them. Also loved the combination of a standard clutch and light flywheel so much we got another monster!