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Shims for the secondary drive gear

  • Thread starter Thread starter fz6rgirl
  • Start date Start date
F

fz6rgirl

Guest
So as I introduced myself, I told a little bit about the problem that I've been having with my 83 1100GL. But I'll do a recap, we bought our bike last April thinking everything was alright with the bike. I work at a motorcycle shop and I've seen the repair orders and what my shop has done with this bike. We had to replace the drive shaft seal in the back cause that started puking oil on the rear tire. That went in, no problem besides a little groaning from the fiance as he was trying to get the original out. Then about a month went on, and him and I went out for a ride. About 30 miles from home, his bike started to make a "ticking" sound. We got it home and put more oil in it and it wasn't leaking anywhere so we thought it was just low on oil.
The fiance rode it to work the next day just fine. No ticking, went through the gears just fine and accelerated fantastic like and it purred like a "mean cat" wanting to get out on the road to open her up. Well, he was on his way home and he didn't even make it out of the parking lot and one of the seconardy drive gears snapped. We took it to my shop where it is currently sitting since late May. We got the gears and my service manager has pressed the gears together, but we are missing some vital parts that are needed to get the bike back on the road. The shims..... Suzuki discontinued them back in 1995. We have almost exhausted all of our options on finding shims for this bike and I'm almost ready to give up on it and find him another one. But I don't want to because this bike was fantastic until the gear broke.
The manangers son told me to buy some copper shim stock and make my own shims. Just trace and cut. Well, little did I know that the shims had to seal the case up. And the shims that my fiance built wouldn't hold the oil in. It would leak out as soon as we would put oil inside. So here I am asking you awesome GS owners if you guys have any ideas on where to go from here. I really don't wanna roll the bike down a cliff, the engine is still good, it only has 40,xxx miles on it. Starts up everytime, electricals work.

Thanks for reading. :-)
 
not sure if this is what your after, but reading the parts fiche seems all parts are still available...

http://www.boulevardsuzuki.com/fich...y=Motorcycles&make=SUZUKI&year=1982&fveh=2159

2159_19.gif


4-2 SHIM DRIVE BEVE
09181-32002 0~3 $4.03 $3.27
4-4 SHIM DRIVE BEVE
09181-32004 0~3 $4.18 $3.39
4-6 SHIM DRIVE BEVE
09181-32006 0~3 $4.18 $3.39
4-8 SHIM DRIVE BEVE
09181-32008 0~3 $3.92 $3.19
4-9 SHIM DRIVE BEVE
09181-32009 0~3 $4.03 $3.27
10-3 SHIM DR BEVEL 1
09181-25008 0~3 $3.35 $2.71
Click to expand...


or am I way off base....
 
Yes, those are what I'm looking for, those are still available through suzuki, but the ones that we really need is #20 and #17. The 2 big shims.
 
Those shims regularly show up for sale on on Ebay. Or, you just buy a used secondary drive gear assembly and replace the one you lost the shims to.
 
fz6rgirl said:
Yes, those are what I'm looking for, those are still available through suzuki, but the ones that we really need is #20 and #17. The 2 big shims.
Click to expand...

And now I see they don't list those.....my bad.....sorry about that

perhaps a post in the wanted section here on the site as well might yield something for you, or as rustybronco said, check e-bay....
 
Hi,

You may already know this but here are the part numbers, slightly different part numbers for different thicknesses...

#17 24945-45101
SHIM (T:0.30)

#17 24945-45100
SHIM (T:0.35)

#17 24945-45102
SHIM (T:0.40)

#17 24945-45103
SHIM (T:0.50)

#17 24945-45104
SHIM (T:0.60)


#20 24935-45101
SHIM (T:0.30)

#20 24935-45100
SHIM (T:0.35)

#20 24935-45102
SHIM (T:0.40)

#20 24935-45103
SHIM (T:0.50)

#20 24935-45104
SHIM (T:0.60)

Most of these same part numbers show up as being used on several model bikes. It may help you in your used parts search...


  • 1979 SUZUKI GS850GN - SECONDARY DRIVE GEAR
  • 1980 GS850GL - SECONDARY DRIVE GEAR
  • 1980 SUZUKI GS1000GLT - SECONDARY DRIVE GEAR
  • 1980 SUZUKI GS1000GT - SECONDARY DRIVE GEAR
  • 1980 SUZUKI GS850GT - SECONDARY DRIVE GEAR
  • 1981 SUZUKI GS1000GLX - SECONDARY DRIVE GEAR
  • 1981 SUZUKI GS1000GX - SECONDARY DRIVE GEAR
  • 1981 SUZUKI GS850GLX - SECONDARY DRIVE GEAR
  • 1981 SUZUKI GS850GX - SECONDARY DRIVE GEAR
  • 1982 GS1100G - SECONDARY DRIVE GEAR
  • 1982 SUZUKI GS1100GKZ (Touring) - SECONDARY DRIVE GEAR
  • 1982 SUZUKI GS1100GLZ - SECONDARY DRIVE GEAR
  • 1982 SUZUKI GS850GLZ - GEAR SHIFTING
  • 1982 SUZUKI GS850GLZ - SECONDARY DRIVE GEAR
  • 1982 SUZUKI GS850GZ - SECONDARY DRIVE GEAR
  • 1983 SUZUKI GS1100GD - SECONDARY DRIVE GEAR
  • 1983 SUZUKI GS1100GKD - SECONDARY DRIVE GEAR
  • 1983 SUZUKI GS1100GLD - SECONDARY DRIVE GEAR
  • 1983 SUZUKI GS850GD - SECONDARY DRIVE GEAR
  • 1983 SUZUKI GS850GLD - GEAR SHIFTING
  • 1983 SUZUKI GS850GLD - SECONDARY DRIVE GEAR
  • 1984 SUZUKI GS1100GKE Touring - SECONDARY DRIVE GEAR
And now the real reason I'm here. I know you posted in the "New Members Click Here" thread but that's not really where you're supposed to make your introductions. So I'll give you your S.W.A.G. right here. :)

If you are here you probably have a 30 year old motorcycle that needs about 20 years worth of maintenance. You'll find all kinds of helpful tips, procedures, manuals, etc, in the links below. Let's get started.

Let me dump a TON of information on you and share some GS lovin'. :D

I just stopped by to welcome you to the forum in my own, special way.
big_hi.gif


If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....
hat1.gif


Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. This is what NOT to do: Top 10 Newbie Mistakes. Now let me roll out the welcome mat for you...

carpet.jpg


Please Click Here For Your Mega-Welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike! :D

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff
 
It's alright. I will try Ebay. I did see a few of them on ebay awhile ago, but didn't act on them because we were in the middle of making the shims out of the copper stock.
 
Thank you guys so much! I think we are getting back on track to getting her back on the road! You guys have been a HUGE help.
 
Just one correction -- the shims do not have anything to do with sealing the gear assemblies to the engine cases.

That is handled by the large o-rings, #16 and #18. If gear oil is reaching the shims, these o-rings are leaking.
 
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