Sheared the Starter Clutch Bolts Again

[Guest]

Hello:

The three bolts holding my starter gear to the flywheel sheared last year, so I made the repair this spring.

So I put about two hundred miles on the bike (1983 GS1100ED), and I began to hear a knocking sound at idle. Then the battery light went on, and the starter just spun and spun, rather than engaging and starting.

So I removed the sidecover and the flywheel, and guess what? All three bolts holding on the starter gear were once again sheared off.

Am I doing something wrong that is causing these bolts to break?

At this point, it is an easy fix, but I would prefer to fix it once and for all.

Any advice?

Thanks so much for reading.....

[Agemax]

did you loctite them in and torque them when you refitted them last time?

[gearhead13]

What grade of bolts did you use? Grade 8 at least IMO.

[CCM911]

Loctite - yes. I tightened them as tight as I can.

But I used the factory bolts. This time I am moving up to Grade 8 at the least!!!

[ptexotik]

Have it welded, and fawgedabowtit!

[tom203]

Isn't there a modification to delay ignition firing till starter comes up to speed to avoid kickback on these monsters.?

[gearhead13]

I always go well past factory torque specs on these especially with good grade bolts.
Use a torque wrench, it is held on not only by the bolt itself but also by the friction between the two when it is torqued down. Hard part is holding it to torque, get creative without messing up the rotor.

[Agemax]

tighten them too much and you will stretch and weaken the bolts

[oldgrumpy]

Hello:

The three bolts holding my starter gear to the flywheel sheared last year, so I made the repair this spring.

So I put about two hundred miles on the bike (1983 GS1100ED), and I began to hear a knocking sound at idle. Then the battery light went on, and the starter just spun and spun, rather than engaging and starting.

So I removed the sidecover and the flywheel, and guess what? All three bolts holding on the starter gear were once again sheared off.

Am I doing something wrong that is causing these bolts to break?

At this point, it is an easy fix, but I would prefer to fix it once and for all.

Any advice?

Thanks so much for reading.....

...................hi you brobably used the wrong grade of bolt... and don,t over tighten ,, use some loctite regards oldgrumpy

[rapidray]

Put new bolts in it & WELD THE STARTER CLUTCH!!! Ray.

[CCM911]

Does anyone have the bolt sizes I will need, or will I have to order the faactory ones and then match up at the hardware store?

[rapidray]

You will need to go to a "specialty" fastener store or order online to get what you need. I would just order them from Suzuki. Ray.

[blacksmoke611]

Bringing this thread back to life.. I just sheared my bolts off. I have access to grade 12 bolts through my work. but ive read you can drill tap to m10 bolts, which sounds good. but I also hear of welding it, but where exactly and what points do you weld at?? thanks

[ptexotik]

Bringing this thread back to life.. I just sheared my bolts off. I have access to grade 12 bolts through my work. but ive read you can drill tap to m10 bolts, which sounds good. but I also hear of welding it, but where exactly and what points do you weld at?? thanks

3 welds, approx 1-1.5" long ... above each of the loctited OEM bolts, joining 'clutch' to rotor.
maybe someone has a photo?

(I would steer away from tapping for larger bolts. just my 2c)

[quexpress]

I would steer away from tapping for larger bolts. just my 2c

Why? Just wondering because that had sounded like a very good idea to me and I had intended on doing that.
However I have no experience with these starter clutch bolts ... yet.