Starter Clutch Broken 1135 GSX

[GS110X506158]

http://www.thegsresources.com/_forum/album.php?albumid=501

Hi there biker friens..
Butiful day here in Norway, but i struggle to unlock the retainer nut that keeps the stator / starter clutch assy on the shaft. How is this nut normally fixed-sequred..loctite? I read some post here in this exelent forum that mentioned some smart tool to use, but forgot the link.
I am sure a lot of you have done this job before as i understand its a common problem that this part is broken. Please advise me how to proceeed. I put some pictures in my album, link above.
Regards Espen

[posplayr]

Welcome abroad, the nut comes off pretty easy using a impact wench (electric or pneumatic) without having to lock the rear wheel.

You will then need to find the correct puller. U have the puller?

I clean everything and use red lock tite on the threads and the taper when doing reassembly.

It can be a bear to get off and heat is required. Don't get the magnets on the rotors hot or the magnets will fail.

[GS110X506158]

Hi Posplayr, tnx for reply..
No i dont have the puller, is it a special puller from Suzuki or will a normal puller be ok? Mayby someone have a picture and description of a puller that works. You mention to use heat, is this a must?
Regards Espen

[rapidray]

Use the FACTORY Suzuki puller & do NOT use any other puller! You need an impact wrench like Jim said to get the nut off & then the Suzuki puller. Ray.

[GS110X506158]

Thanks RapidRay, i will ask Suzuki for the price for the puller. Is it normal to overhaul this assy or do i have to buy a new?
Regards Espen

[GS110X506158]

I noticed that the 2 washers for the starter idler gear is missing ( item no 3)

http://www.thegsresources.com/_forum/album.php?albumid=501

Do all 1100/1135 models have these originally?
Regards Espen

[posplayr]

Well a Ray says Suzuki stuff is the best, with a price to match. There are alternatives and they seem to be getting better.

Normally just use advanced search function and this stuff will come up pretty easily.

http://www.thegsresources.com/_forum/showthread.php?t=141742&highlight=rotor+puller

P.S. Ray taught me the impact trick

[GS110X506158]

Thank again! Exelent link you gave me..now i know what rotor-puller to look for and what gas to use for heating.
If sombody could verify that i also need to buy the washer's item #3 for the starter iddler gear..
Do sombody have picture or sketch how the starter clutch assy is build up so i can study and understand how it works before i open it?
I guess you all get bored of this now..anyway thanks again, i will put out some pictures afterwords.
Regards Espen

[posplayr]

There are certain parts like the OD of a hub on the large gear that just need to be replaced. The price has gone up some to about $104 from Flatout but just change them to new unless you have a know good one.

[GS110X506158]

I will have to meassure the OD for the large gear's hub. Where to find these data?

If sombody also could verify that i also need to buy the washer's item #3 for the starter iddler gear..
Do sombody have picture or sketch how the starter clutch assy is build up so i can study and understand how it works before i open it?
I guess you all get bored of this now..anyway thanks again, i will put out some pictures afterwords.
Regards Espen

[posplayr]

when you get it off, you will figure it out. It is a Sprag clutch that locks in one direction. There are Barrels being pushed out with springs which run agains the OD of the hub on the big gear. In one direction the barrels are pushed back, in the other direction they wedge against the OD of the hub locking the clutch.

http://en.wikipedia.org/wiki/Sprag

both barrels and the OD wear. after you get it off, you will find it best to replace the whole thing

[SqDancerLynn1]

Worst case trailer it to the dealer and have them remove it

[posplayr]

http://www.thegsresources.com/_forum/showpost.php?p=868390&postcount=3

I found the measurements for a wear limit on a starter clutch.

The barrals measure:

14.80, 14.74 and 14.59 mm compared to new which is 15.00 mm

The flywheel boss is

51.48 mm v.s new which is 52 mm.

If I take either of two other flywheels and drop it into the clutch the barrels lock. With the "new" one just pulled out it will NOT ; it simply spins.

Clutch is worn out; all of the sprage clutch surfaces have been machined down inside my motor

FYI I forgot to put the bearing in and it wore the clutch till it would not run anymore.

[GS110X506158]

Tnx a lot for this info, i have not done anything yet so i have not checked this out.
I went to dealer today and found out that these parts are expensive. Also i checked some old microfilm for 1150 that show only one roller bearring and there is no washer for the starter idler. Maybe my 1100EF motor dont need the 2 washers #3 (front and back idler gear ) I am confused about this. Anyway i will find out moore after takingit apart. Regards Espen

[first timer]

here you go take a look at this, this is for your 1980 1100 motor, looks like you need 2 #3 washers. Might want to pull your oil pan if you only have 1 these guys have a tandency to fall off when removing and installing then floating in the motor.

http://www.bikebandit.com/assets/schematics/Suzuki/SU0061_009.gif

and this for prices

http://www.bikebandit.com/suzuki-motorcycle-gs1100et-1980-starter-clutch/o/m5996sch270795