Is this starter clutch history?

[littleroot]

I finally removed my starter clutch. I found the three hex bolts loose, but before I could tighten them I had springs and pins falling out. One hex bolt is showing some wear but I thought, gee, if I just replace that and figure out how these springs and pins go together I'm all set.

However, on closer inspection I found the main piece is fractured, and that perhaps the pins tried to escape out the sides as the outer ring is punctured in three places.

So what do I need and from where should I get it? I think Bike Bandit has the starter clutch assy for $240.

Pics below

One bolt in the upper left seems to have some heavy wear

Note the two places along the outer edge where apparently the pins wanted OUT! Also the fracture is seen in the bottom of the image

Close up of the fracture. I wonder if someone tried to weld it or something because to me it looks discolored

 

[omaharj]

I think I have that piece (from a 1100G ) Would it fit? Then new pins and springs (bet the springs are sproinged) and you're back in business. I'll go to the garage now and look.

 

[omaharj]

Yeah, I've got it in my hand now. Let's confirm it will work and then take the next step

 

[littleroot]

I think I have that piece (from a 1100G ) Would it fit? Then new pins and springs (bet the springs are sproinged) and you're back in business. I'll go to the garage now and look.

Hi, what year is the 1100G? I'm not sure how to find it it is the same. Can I check bike bandit and see if the suzuki part numbers match?

 

[TheCafeKid]

The 1100G is its OWN design, so it will HAVE to come from an 1100G/L to work. Recently Blowerbike, and myself went thru a bazillion different combos from other bikes trying to piece together a complete starter clutch, Primary gear etc. Not happening. It seems to use the rotor from the 16V 1100, but the clutch of a 750, primary gear of the 1100, and then its own bolt pattern.

At any rate, RJ, yours will work for his bike. However, I will caution you that you need to rebuild the ENTIRE package. Do not attempt to simply repair the springs or the rollers or whatever... As you can see in the pics you posted, the clutch was trash whether it was cracked or not. The holes punched out of the casing by the throwout and pushers are what the problem ends up being, but you will also see that your primary gear (not pictured) will be pretty worn out too. You can attempt to reuse these peices at your own peril, but from experience, if you dont use a complete known GOOD assembly, used or new, you will eventually end up in the same boat you are now..

In short, RJ if you have a FULL assembly, including a primary gear to sell this gent, he would be better off. If not, I would also shop around for a GOOD used primary gear. Double check your bearings as well, and make sure your crank snout isnt trashed too...

 

[littleroot]

Great info.

Do you know if the OEM Starter Clutch Set, aka, 12600-49850 , includes bearings?

Link to fiche from Bike Bandit

My chamfer "thrust" washer looks OK, but i would probably buy another one, plus the two bearings and the two starter idle washers (mine has none!), but I would like to know what comes in the "set" first to avoid duplication.

Thanks!
-Bob

The 1100G is its OWN design, so it will HAVE to come from an 1100G/L to work. Recently Blowerbike, and myself went thru a bazillion different combos from other bikes trying to piece together a complete starter clutch, Primary gear etc. Not happening. It seems to use the rotor from the 16V 1100, but the clutch of a 750, primary gear of the 1100, and then its own bolt pattern.

At any rate, RJ, yours will work for his bike. However, I will caution you that you need to rebuild the ENTIRE package. Do not attempt to simply repair the springs or the rollers or whatever... As you can see in the pics you posted, the clutch was trash whether it was cracked or not. The holes punched out of the casing by the throwout and pushers are what the problem ends up being, but you will also see that your primary gear (not pictured) will be pretty worn out too. You can attempt to reuse these peices at your own peril, but from experience, if you dont use a complete known GOOD assembly, used or new, you will eventually end up in the same boat you are now..

In short, RJ if you have a FULL assembly, including a primary gear to sell this gent, he would be better off. If not, I would also shop around for a GOOD used primary gear. Double check your bearings as well, and make sure your crank snout isnt trashed too...

 

[littleroot]

More photos 1

More photos 1

 

[littleroot]

More photos 3

More photos 3

 

[littleroot]

More photos 4

More photos 4

 

[littleroot]

More photos 2

More photos 2

 

[Carter Turk]

I have a brand new primary gear supposedly for an 84 1150. However, it did not fit.
Its a 31mm OD. I need the 35mm OD. I bought from Temecula Motorsports and did the run around with the parts guy regarding the starter clutch assembly not fitting my bike. If you cant find the whole assembly let me know. It appears this primary gear runs the dual roller bearing setup, mine has the single roller bearing.

 

[Tom MLC]

BikeBandit part numbers ARE NOT Suzuki part numbers. Unless they have changed their fische. To my knowledge, they use proprietary numbers which do not cross from different models. Alpha Sports and PartShark are better sources for cross reference. They DO use Suzuki part numbers.

Glad to see you are getting your scooter back together. Still a few months of good riding weather. I'm ready to hit the road. Say it.

 

[TheCafeKid]

I have a brand new primary gear supposedly for an 84 1150. However, it did not fit.
Its a 31mm OD. I need the 35mm OD. I bought from Temecula Motorsports and did the run around with the parts guy regarding the starter clutch assembly not fitting my bike. If you cant find the whole assembly let me know. It appears this primary gear runs the dual roller bearing setup, mine has the single roller bearing.

Actually from what we've found, and bare in mind we havent EVERY single model used to go thru, so dont take this as the gospel, but the models that used TWO bearings ended up being the same size at ONE larger bearing. MOST of the problems in getting different models to work either came from the bolt alignment, the clutch being to large or small, or, and the most common issue, was the snout on the PRIMARY gear. It was either too big or too small. At first, we thought there seemed to be only two different sizes, but further examination revealed that the primary gear in the 1000/1100G used its OWN size even still. This was pretty confusing, since we all know Zook didnt like to re-tool, we just assumed that they'd stick to using one small one, and one larger one, and NOT make one for ONE specific model. We were, apparently, wrong. Im still not sure why they simply didnt use the set up from the 1100Es, as it was a stronger assembly, and so far as ive seen, not prone to the break down that the large Zooks seem to suffer from.

 

[blowerbike]

it looks like your alt. rotor(3) holes are elongated.
you will have problems in the near future if you use your rotor.
if possible.......
find someone who removed there entire assy. from the main bearing out from a low milage engine as drag racers do and buy that.
stick with known 80-82 1100E parts for less confusion.
if you have deep pockets....
find the best price on new parts and order those.
yours is one of the worst starter clutch assy. i have ever seen.
start from scratch if this bike is a keeper.

 

[wkmpt]

There's some good OEM parts diagrams at DGY.com with mfr part numbers.
http://www.dgy.com/fiche_select1.asp?cat=Motorcycles&mfg=SUZUKI&srt=yr

 

[littleroot]

it looks like your alt. rotor(3) holes are elongated.
you will have problems in the near future if you use your rotor.
if possible.......
find someone who removed there entire assy. from the main bearing out from a low milage engine as drag racers do and buy that.
stick with known 80-82 1100E parts for less confusion.
if you have deep pockets....
find the best price on new parts and order those.
yours is one of the worst starter clutch assy. i have ever seen.
start from scratch if this bike is a keeper.

A rotor, too? Bummer! Boy, this is getting more fun by the minute. $267 for the rotor? OUCH

I don't have deep pockets but I did decide to buy the "CLUTCH SET, STARTER" from BikeBandit.com today.

Wish me luck