Starter Clutch Broken 1135 GSX

[GS110X506158]

Frame is 1980 mod, i think motor is about 1984 1100EF (1135CC, 36mm carb)
If i look in microfilms for 1150 from 1984 there is only 1 roller bear #8, and on the idler there is no washer at all (neither in front or in back)
I am 100% sure i did not drop any washer, and now i get a strong feeling that these washers have never been there either. I am sure one of the guys in this fora that knows my 1135 can confirm.
Regards Espen

Here is the link to 1150 starter clutch assy: http://www.bikebandit.com/suzuki-mot...m6013sch268915

[posplayr]

Well I'm sure you need the roller bearing #8. That was the issue the last time I installed my starter clutch; I left it on the bench for a long time and forgot #8. So the starter ran on the clutch barrels and wore out in 2K miles.

Not sure about #9. I think it is needed but somehow affixed to the crank end.

[GS110X506158]

Tnx again, time will show what's there. In my 1150 manual, downloaded yesterday its mentioned a thick slotted copper thrust washer to be mounted with chamfered side facing in. Is this always made from copper #9 ? I will anyway check for wear.
This manual does not mention the 2 pcs washers #3 on the idler gear as the GSX 1100 does. Regards Espen

[woodman]

Measure the OD of the threaded part inside the hub. My 80 meausred 35mm not 30 so this is the one I ordered http://www.motionpro.com/motorcycle/partno/08-0349/ the inside diameter of the hub on the ring gear where the clutch bearings ride measures 52.17mm on mine with no sign of wear. My bike has the 2 washers on the idler gear as shown in the bikebandit 1100 diagram below, but not in the 1150 one. Whether thats right for yours I cant say. Im just trying to help here, but I am by no means in the same league as the others posting on this subject for whatevre its worth. Mine is apart, if you need any other measurements just ask

[posplayr]

the inside diameter of the hub on the ring gear where the clutch bearings ride measures 52.17mm on mine with no sign of wear.

Not sure what ID you are measuring. The critical dimensions for both big end and small end is

15mm OD of the barrels #4
52mm OD of the hub on the ring gear part os set #3

Prices have gone up Flatout used to be $94 now it is $118

As noted in the measurements below it doesn't take much wear (0.25mm and 0.5mm on #4 and #3 respectively. There are the actual measurements of a clutch failed due to excessive wear not having the inner bearing.

I have also done the comparision of 3 big end 1100E clutches, 1 small end 1100 clutch and a 80-81 750E starter clutch.

Quote:
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

[GS110X506158]

Hi again, now waiting for the puller..

http://www.repairmanual.com/catalog/DS-MP14

Price about 270NOK included tax and shipment

Norwegian original Suzuki about 1200NOK

Espen

[woodman]

I just got my new puller today and it fits both my 1980 and 82 GS1100E. I tried it on both bikes. It measures per Motion Pro M35 X 1.5 RH internal thread X 75 MM. It was $36.50 with $6.50 shipping. Apparently the 1150s & some 1100s take the 30mm puller. I was measuring the flat part just outside of where the starter clutch rides where mine is buggered up

[woodman]

Some days the bear eats you. I got my new puller & pulled the good one {I thought} off the 82 parts bike and its in worse shape then my original one. Thats $43 for nothing but at least I still have the tool. Hope your results come out better with your 1150

[GS110X506158]

Hi, I got the puller today, it worked great (no need for heat this time). Its obvious what had happend, chk the pictures: http://www.thegsresources.com/_forum...pictureid=3056

All the hex-bolts broken, and the brass/cupper disk/washer have got some marks and oval holes. The assy grip perfect in one direction and slips the oposite way. I think i will try with new bolts..comments?
Regards Espen

[posplayr]

What is the OD of the barrels and the hub on the large flywheel? This is one of those times when you really need a digital caliper.

Compare to the measurements i already gave.

The wear on the copper spacer looks minor, but there seems to be some embedded into the back of the rotor?

[GS110X506158]

Hi Posplayr,
OD is about 52mm, and the barrels have dia about 15mm.
Heres all the pictures: http://www.thegsresources.com/_forum...hp?albumid=501

[GS110X506158]

Hi again,
Yes, there is some metal on top of the flywheel surface, i will clean it all well and check for marks. The flywheel runs very nice on the roller bearring, but i will meassure it up and check for a replacement. Here in Norway everything is quite expensive, but i remember your advice to replace this.
Tnx again for all help, hopefully i will manage this repair before vacation starts.
Today its so hot here, that the whole family just relax in the childrens plastic toy 5000l pool. Right now, about 21.40 evening we have 26centigrades in shadow. Pool have about 26 deg also.
Regards Espen

[argonsagas]

Hi again, now waiting for the puller..

http://www.repairmanual.com/catalog/DS-MP14

Price about 270NOK included tax and shipment

Norwegian original Suzuki about 1200NOK

Espen

I forgot that name when I first read this thread.

The name threw me off when I was looking for a puller, but I tried them and was very pleased. Their tools are definitely good quality.

Customer service is also excellent. When mine was delayed several weeks I wrote to them and they offered another, free of charge.

The original one arrived a day later, having been held up by Customs, but I was very pleased with the offer..

[posplayr]

Hi Posplayr,
OD is about 52mm, and the barrels have dia about 15mm.
Heres all the pictures: http://www.thegsresources.com/_forum...hp?albumid=501

There is only about a 0.5mm and 0.25mm wear limit on both respectively.

[GS110X506158]

Now after reassembly i wonder if i made a mistake..used to much Loctite (permatex red gel) and filled the gap between head of the allen-bolts and flywheel. This will not harden and i think i have to wash it out again to prevent it from coming into the oil.
Pictures attached: http://www.thegsresources.com/_forum...hp?albumid=501