starter clutch and the "inside" of the stator

I am referring to shims that space the stator away from the engine cases. Keith called them dampers. In any case, they are in different thicknesses. LOOK AT YOUR MANUAL. There will be a picture showing the stator and cases and the gap between where you are supposed to make a measurement. If the gap is out of spec, the wheel that engages the starter gear won't be contacting correctly and will either not work or just spin.

I take it from your comment that you need a rotor with the keyway thing so it won't spin on the crank? Have you considered a bike salvage yard or eBay? Don't beat on the thing when pulling it off otherwise you will demagnetize it. The versions of the rotor that don't have the keyway stay in place by torquing the bolt that holds the thing. How did you do this? I have an impact driver (A unit called the THUNDER GUN) and have never had one loosen even though I had the type with no keyway slot to hold it mechanically. A couple zaps with the gun were all that were needed.

i used a torque wrench to spec.(50ft lbs) i gues this a case where you screw the spec. there is no woodruff key in the crank only a slot in the stator. you are right the shims were working though cuz the bike was cranking and starting till it sat over night. what about grinding a key spot in it? i have a third rotor though it is my last one, .......... i have a rattle gun but i went with spec from the book. go with the gun?

I don't use a torque wrench on that bolt. It is stout. I hit it with an impact driver. Don't know about a slot in the crank. Have you ever tried drilling the crankshaft? IT IS HARD! I am not sure how you would do it. Put some red Loctite on the bolt and hit it with the gun.

ok i was thinking grinding it, dremel cuz it is the same shape as the woodruff key.

something is not right....my bike had no slot for key on crank or stator (that i saw and i had it apart twice).i red locktighted the three allen heads that hold the clutch to stator and tightened the snot out of them and
red locktighted the bolt that goes in the end of the crank and had the wife step on the brake in gear and socked it up pretty good....if you use locktite and crank those 4 fasteners pretty good, it should nt be spinning or coming apart....redline cycle has a good write up with pics on when to tell your parts are toast...very informative read..

thanks i'll look up the article

i rattle gunned it on and sofar so good!
thanks