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Well, I was finally able to change out my Vision's starter sprag (aka Starter Drive Clutch) gear. A big shout out to Noe Martinez and others that pointed out the issue. Sadly (Eric the) Red had never been out in really, really cold frickin' weather to try to start. What happened is we moved from the south (N. Alabama) to SE Wyoming.....in February....Red (with little fanfare) started easily while in the trailer (the horror, the horror) but had to be shut down to unload and when it was time to put it in the garage upon the restart attempt it didn’t, I hesitated on the starter switch and it made that funny (now sickening ;-) ) little “clink” sound and the starter just spun. *&$^#% “sprag” gear broke. I thought I read about it in passing but some people just gotta learn the hard way…....At any rate the job is probably about 2 hrs....IF you have ALL the tools (and can find them). I laid Red on the right side and pulled the shifter/floorboard assembly, the clutch Cable (Carefully rotate the pinion shaft with an adjustable spanner (AKA “crescent wrench) clockwise, and then removed the cap plate, pulled the clutch pinion (not sure that was necessary but…..) and then pulled the primary cover off. The primary cover came off OK (more later). I then removed the center bolt on the flywheel in the process learning that keeping the crank from turning (without the 2 zillion dollar tool (2ZDT)) proved challenging. A plastic handled scraper (PHS) sacrificed it's end piece and when placed the same as the 2ZDT (in the service manual) the PHS served well. I pulled off the flywheel with the special tool (as noted by several people thank you) a drain plug from (an) 85 model Subaru (Who knew ;-) It really works too....) with little fanfare. I then removed the Crankshaft Gear (Primary Drive Gear) behind it and then removed the Starter Drive Clutch (sprag) gear. Oddly enough the sprag “looked” perfectly fine Then again, I’m not certain what “broke/good” should look like). I reinstalled the sprag gear, the Crankshaft Gear (Primary Drive Gear) and then reinserted the flywheel. Then I realized while I had a swell ½in. drive torque wrench I did not have a frickin’ 15MM ½ drive socket (no matter how many times I looked in the toolbox). Off to the parts store (thus the extended repair time) for a new metric socket set (an’t have too many and hey, I got another 10mm to loose…) Got it torqued to 75ft lbs and then began the rest of the reassembly. There is an important thing remember here....Not previously mentioned though obvious…. the primary cover has a million (zillion?) power magnet in it (Capable of lifting steel girders?) that will try very hard to eat your fingers off when trying to reinstall. I have no idea how to avoid it. After getting it back on with most of the skin on my fingers intact I reinstalled all the other stuff and gave it a try. Hallelujah Red lives. Ultimately I wanted to write all this to lay it out and to show a picture of a spag gear - broken no less....as I hadn’t even seen one so here it is.
 

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broken?

Hate to say it but broken, where at? Maybe one of the rollers or races that we can not see. I have never had mine out, but been through a couple of starters now. Starter is a pain to swap out brushes in. Personally it is probably worth taking the starter to a rebuilder if they will do it for a fair price.
The good old primary cover removal...... It has been mentioned on here before. If you have the time and access to a good bolt supplier, take out some of the bolts and go down to the supplier(Lowes, maybe) with the sample bolt, by the longest you can get, cut the heads off and make dowels out of them. Remove all the bolts from the primary cover then insert several dowels, I used about have as many as the original bolts. Then you can use the clutch arm pulled out half way or so as a lever on the back end. Smack the primary if you want with a dead blow hammer if you want to jar it loose. Then try pulling it off a bit. I used some of the "Bondo" body filler plastics to stick into between the primary cover and the engine case. Then you can use small screw drivers, pry bars, or maybe wooden shims to help separate the primary cover away from the engine. Yes taking the cover off or on can(will) get your fingers pinched, be careful........Locking the engine,sometimes you can put a good strong rag in between two meshing gears to get the engine to lock to break bolts/nuts loose from crank, clutch, torque compensator. Hope it is working good now! Enjoy the new home!
 

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Discussion Starter #3
Yea, the "broken" "looked like" a small bearing "guide"(?) in the piece itself. First time I've ever dealt with one. My decision that it was the issue was based on the starter just spinning and Noe Martinez and a couple of others saying that is symptomatic of a bad sprag so I ordered one etc. (Mostly because it seemed cheaper than a starter and I'm a KISS (AKA cheapskate) kind of troubleshooter0) About all I can say is it worked ;-) ...I stared at the two "guides" (basically for the gasket) and couldn't see a fix to the real guide issue. Your suggestions are great!. Right now I'm hoping not to have to remove it for a long time but since "hope" isn't a plan I'll look into some bolts to make some dowels. Lovin' the new place and thanks for the ideas.
 

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Yea, the "broken" "looked like" a small bearing "guide"(?) in the piece itself. First time I've ever dealt with one. My decision that it was the issue was based on the starter just spinning and Noe Martinez and a couple of others saying that is symptomatic of a bad sprag so I ordered one etc. (Mostly because it seemed cheaper than a starter and I'm a KISS (AKA cheapskate) kind of troubleshooter0) About all I can say is it worked ;-) ...I stared at the two "guides" (basically for the gasket) and couldn't see a fix to the real guide issue. Your suggestions are great!. Right now I'm hoping not to have to remove it for a long time but since "hope" isn't a plan I'll look into some bolts to make some dowels. Lovin' the new place and thanks for the ideas.
Thanks for posting the picture of the sprag gear. I always wondered what it looked like.
 

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Glad you got it done and back on the road.
 

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where did you get the sprag gear from. A bearing store or a dealer
 
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