Starter Clutch

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Note: the starter clutch does not have to be taken off to split the cases or remove the crankshaft.

Removal

Remove the upper fairings. See the Upper Fairings topic for more information. 

Drain the engine oil. See the Engine Oil topic for more information.

Remove the nine left crankcase cover bolts with a 5 mm Allen.

The top left bolt has a sealing washer and the farthest left bolt is longer than the rest.

Utilize the pry points to free the left crankcase cover.

Remove the left crankcase cover and gasket.

Remove the dowel pin from the crankcase.

Remove the starter idle gear shaft. It may come out with the crankcase cover.

Remove the starter idle gear.

Hold the starter clutch with a starter clutch holder. Loosen the bolt with a 17 mm socket. Do not remove the bolt yet.

Special Tool - Starter Clutch Holder: 09920-34810

To remove the starter clutch you will need a rotor remover tool.

Special Tool - Rotor Remover: 09930-33720

Order special puller here! http://www.repairmanual.com/catalog/DS-MP39

Back the bolt out enough to allow the starter clutch and gear to come free of the crankshaft.

Coat the threads of the puller in grease. Thread the special puller tool onto the starter clutch.

Hold puller with a large wrench and turn in the pusher with a socket. When the starter clutch becomes free from the crankshaft remove the puller.

Remove the starter clutch bolt with a 17 mm socket.

Remove the starter clutch and gear from the crankshaft.

Inspect the starter driven gear and starter clutch for wear, damage, and function. The starter driven gear should only turn one direction when in the starter clutch.

Installation

Place the starter driven gear boss into the starter clutch.

Place the starter clutch and driven gear on the crankshaft.

Apply a small amount of Red Loctite to the threads of the starter clutch bolt.

Hold the starter clutch with a starter clutch holder. Tighten the bolt to specification with a 17 mm socket.

(Starter Clutch Bolt Torque: 150 N-m or 108.5 lb-ft)

Apply fresh engine oil to the starter idle gear shaft. Install the starter idle gear and shaft.

Install the left crankcase cover dowel pin.

Make sure the left crankcase cover mating surface is clean. Apply Suzuki Bond or an equivalent silicone sealant to the areas of the crankcase as indicated by the red lines.

Suzuki Bond 1207B - 99104-31140

Install a new left crankcase cover gasket. Fit the left crankcase cover to the crankcase. Make sure the starter idle gear shaft will fit into the cover properly.

Install the nine left crankcase cover bolts.

The farthest left bolt is longer than the rest. Install a new sealing washer with the top left bolt. Tighten the left crankcase cover bolts securely with a 5 mm Allen.

Adjust the clutch cable free play. See the Clutch Cable Adjustment topic for more information.

Fill the engine oil. See the Engine Oil topic for more information.

Install the upper fairings. See the Upper Fairings topic for more information.

Copyright - Cyclepedia Press LLC

Note: If you are viewing this document offline be sure to visit the latest version online at http://www.cyclepedia.com before attempting any repairs. Updates are made without notice.