Starter Clutch

[Scot Thompson]

Hi All,

We've had some good help from the forum already, so thanks to everyone.

I am putting together a post on the rebuild of the starter clutch on our 1984 GS1100GK. We found all three bolts sheared and a push pin and spring missing. So far, the rollers and the push pins and the starter gear boss all measure with very little wear and no visible flat spots.

Last night we found an orifice that came out of the stator cover when we pulled it off to show a friend what we are doing. (We're waiting for parts.) My suspicion is it fit into the machined part of the starter clutch where one hole goes through the sheet metal cover to the starter clutch machined part. But, there aren't any drawings I can find showing such a thing. Anybody recognize it? Three pics in all.

Thanks, Scot

[Scot Thompson]

here is the second picture.
Scot

[Scot Thompson]

Here is the third picture.

Scot

[Steve]

On the "Crankcase Cover" fiche it's #3, and labelled "Jet, Oil Gallery", but why not put them all in one post?

[bwringer]

All the oil jets I've seen are brass -- they look like (or are) carb jets.

Is that widget aluminum or steel?

[Scot Thompson]

Hi and thanks.

Last question first, this is my first upload, so maybe I got something wrong, but when I uploaded the pic, the "acceptance" response was, "you have just uploaded the maximum of 1 pic." I could not add another pic, so I did each one separately. I'd like to know how to add the 3 at one time.

By the way, where do you access the micro-fische? I am using Sportland Motors from Urbana. That list # 3 as a part number only and no description.

Okay, the real questions? What is its purpose and where does it go?

It is made of steel, not brass.

One other concern I have regarding the starter clutch. On the stamped metal cover to the machined part, there always seems to be a hole going through to one, and only one, of the cavities that the push pin and spring fit into. What is the purpose of this hole? I have looked at starter clutches from other manufactureres and I haven't noticed this hole before, but on every picture I have found of the Suzuki GS xxxx engines, that hole is there. The push pin slips right through it and only that sheet metal cover keeps the push pin in...and it eventually gives way.

thanks, Scot

[Scot Thompson]

Here is another couple of photos. This hole is in all the photos of the Starter Clutch I have seen. Anyone know its purpose?

Scot

[chef1366]

I don't remember seeing that hole on any of the starter clutches I've worked with .
I could be wrong though. It happens

[Scot Thompson]

Thanks Chef,

My fix for the hole was to weld it and also to weld the two other locations where the push pins could punch through the metal cover. Then filed the welds to balance. That is now done and we're waiting on parts to put it back together.

Farther down in my post is a "jet, oil gallery." It came out of the crankcase cover we think. Any idea where it belongs? Or its function?

Scot

[chef1366]

Thanks Chef,

My fix for the hole was to weld it and also to weld the two other locations where the push pins could punch through the metal cover. Then filed the welds to balance. That is now done and we're waiting on parts to put it back together.

Farther down in my post is a "jet, oil gallery." It came out of the crankcase cover we think. Any idea where it belongs? Or its function?

Scot

Need to talk to a shafty guy. I have no idea where that goes. The only oil jets I have in that area are for the crank bearings.