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Finally got the flywheel off my 1983 1100G...this is what I found. All but one of the internal parts looked to be in good shape. Two things that I found, the 3 bolts were not loose but not tight. They unscrewed without much effort with an allen wrench. The screw threads are still in good shape. I did find that one of the holes in the starter clutch that holds the spring and push pin was damaged. See the attached pic of the damaged hole. The spring and push pin slide in and out of the damaged hole with no restriction but the push pin can waggle inside the hole approximately 1/16th of an inch. While the push pin in the other holes has no side to side movement. I didn't find any foreign pieces of metal inside the engine cover. I already have bought new springs, push pins, sliders. Couple of questions...what could have caused this damage? Could it have been a defect from the factory? Do you think that I could just replace the parts and tighten the three bolts and go with it or should I try and find a new starter clutch? Btw, this whole think started because I was getting the "crack" sound when starting the bike but it started right up. Then the last time I rode the bike, I almost couldn't get it started and was close to draining the battery. I case anyone is wondering...it is impossible to push start an 1100G on a flat South GA street by yourself.
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Pic of a good starter clutch hole. -
Be sure to see this post (from beginning)
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Yeah, I always look for a downhill for bump starting1981 gs650L
"We are all born ignorant, but you have to work hard to stay stupid" Ben FranklinComment
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I would replace everything but the rotor and possibly rear bearing.
Spacer is junk, the bur in the hole makes the plate junk and the weird circular patterns tells me the dowels are junk.
You may be able to use the springs and pistons (guides).Last edited by chef1366; 04-02-2014, 04:56 PM.1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
1985 GS1150ES stock with 85 Red E bodywork.
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Also, check the two bearings that the big gear rides on.
After a few whacks, the rollers tend to pop out of the needle bearings
Also, is the round face where the starter clutch rides on the big gear still round, or does it look hammered?
AMHIK1978 GS 1000 (since new)
1979 GS 1000 (The Fridge, superbike replica project)
1978 GS 1000 (parts)
1981 GS 850 (anyone want a project?)
1981 GPZ 550 (backroad screamer)
1970 450 Mk IIID (THUMP!)
2007 DRz 400S
1999 ATK 490ES
1994 DR 350SESComment
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Oh yeahOriginally posted by Big T View Post
The part that rides in the clutch. From the looks of things that may need to be replaced too.1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
1985 GS1150ES stock with 85 Red E bodywork.
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Replaced the Starter Clutch set, pushers, rollers and springs this weekend and the bike starts right up and with no "crack" sound. Couldn't have done the repair without the GS forum. Thanks for your replies!!Comment
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Guess I spoke too soon...Got the "crack" sound this morning. What the hell is causing that??Comment
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How did the boss on the big gear look?
That's the parts you put the starter clutch into1978 GS 1000 (since new)
1979 GS 1000 (The Fridge, superbike replica project)
1978 GS 1000 (parts)
1981 GS 850 (anyone want a project?)
1981 GPZ 550 (backroad screamer)
1970 450 Mk IIID (THUMP!)
2007 DRz 400S
1999 ATK 490ES
1994 DR 350SESComment
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I replaced the big gear too on mine. It seemed to be too big for the bearings. Also, as I recall, it is now a single bearing, not two as shown on the parts fiche. I'm hoping that I got the bolts tight enough. I had some cracks near the pins, too. Mine worked, but rattled badly at idle.sigpic Too old, too many bikes, too many cars, too many things
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Charge your battery
seriously1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
1985 GS1150ES stock with 85 Red E bodywork.
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