New to me GS500 won't start start, starter makes weird spinning noise

[nmr]

Edit: fixed links

So I bought my first bike last week, '06 GS500 It's great so far.

I have a story to tell and a few questions about it. Pics are pretty huge.

Anyone recognize this bike from the Portland area? Curious to know more about some of the work that's been done to it.

Here's a pic:


Bought the bike on Thursday. Went to start it Friday and ... whaaa... what is this weird noise?

Weird starter noise video: https://docs.google.com/open?id=0B7-BdrVIl7V9dlUtZFpxZTc2cjg

After a day or two of f%$king around with trying to push start it, charging the battery, looking up service manuals, scratching my head, reading the forums here, and mostly just cursing because I didn't want to buy a project I cracked open the generator side case:


(Thank you  Starwalt and all of the other people that have posted work threads, their work gave me all the information I needed about the starter system to get the bike running again.)

And then... what's this? This bolt is completely loose? The fuh...: https://docs.google.com/open?id=0B7-BdrVIl7V9cmdlN2NWR1A0SmM

And the whole starter clutch/gear/magnent rotor slid right of its taper. I checked everything for damage, but it seemed fine.

Is this bolt supposed to be threadlocked in? Does anyone know the torque spec on it? I tightened it down as hard as I could with the ratchet I had, put it back together, and she fired right up. Beauty.

Hmm, some wrench marks on the starter clutch wrench flats. Looks like someone has taken it off before ...:

(I'm assuming the brown stuff is epoxy for the magnets.)

Makes me wonder if the starter clutch had been replaced before.

Since I'm new to bikes I have a bunch of random questions:

What is that hose with the bolt stuck in the end of it? ...:


My license plate is mounted way under the tail of the bike, curved around the inside of the fender. Anyone know whether that's good enough for Oregon law?

And the clutch doesn't seem to let go 100% when the lever is pulled all the way in and the bike is in gear, it still pulls just a bit (not enough to roll, but almost.) Should I just take up some of the clutch cable with the adjuster on the clutch cover?

[nmr]

BLACK KEKEKEKE

[Big Rich]

Take that bolt out - that hose is the air box drain.

The clutch should be adjusted at the cover if necessary. The end by the grip should be adjusted for lever free play.

I'm not sure of Oregon law, but with a plate anywhere other than where it should be, you're just asking to be pulled over.

[bucket_chemist]

I have a 2007 F and the starter clutch assembly came loose a couple weeks ago, just like yours. Sorry I can't help with the torque spec; I had the dealer put it back together for me. I'm the second owner of the bike - PO only put 432 miles on - and it's now at 9500 miles. Never been abused, always maintained. Just one of those things, I suppose. My dealer said they haven't seen it before.

Enjoy your new ride.

[jacob_ns]

The starter gear and clutch are held in place by a free floating shaft. OP, check the starter splined shaft itself.

[Dizzledan]

I've had similar troubles with my charging system. Ended up doing a thread on it:
http://gstwins.com/gsboard/index.php?topic=59202.0

The bolts on my starter clutch (attached to the back of the magneto) backed out and wouldn't let the starter system turn. In addition I plopped off my magneto and broke it while trying to fix, so I had to buy a new one.

Your Magneto is missing the epoxy on most of the magnets. This is a sign that they may come loose and wreak havoc on your engine. Get a new magneto now to save your engine down the road.

I used one from an 80' GS250 (30-40 on ebay). You may need to shorten the magneto bolt 1/4" and use some threadlock.


Edit: The reason it wont start, is because the magneto (and starter clutch attached to it) need to be secured onto the crankshaft in order to turn it. You can pop that bolt back on and snug it down really well and it will work, but given what I see with the magnets (search: 'goats') you should get a new/used magneto ASAP.

[Got2bnu]

2006 gs500f starter clutch fix,
Starter clutch has three bolts holding it to flywheel, they are weak and stretch or even break, makes ticking sound similar to cam chain ticking noise, can cause no start, burning out starter, engine bad idle or lose of power due to high resistance.
So easy,
Drain oil, take off two left covers,
Take off fly wheel bolt,
Buy at ace hardware- 3+ inch 14mm X 1.5 bolt coarse thread ($3), put in hole of flywheel, tighten, bolt pushes against crank shaft and pops off, (don't use gear puller or dent puller or pound on flywheel with hammer).
Three bolts hold starter clutch to flywheel if bolts are broken or stretched, they are 8mm X 1.25 Allen 12.9 hard metal, ace hardware (.50 cents ea), (match to old ones)
If bolt are broken in flywheel, drill hole through center of bolt, small enough to not damage threads on flywheel, tap in small Allen or flat head screw driver and back out bolt,
Inspect clutch parts, (three- springs, push rods and round/ flat bearings).
Put back together, use locktite on three bolts 15 lb torque i did about 25 lb, 15 felt to low,
and flywheel bolt 110 lb torque, (again use locktite). Little under 3qts of new 10/40 oil, ride again.
Do it right the first time, oh check tire pressure weekly with good not cheap tire gauge,
Best starter bike out there

Got2Bnu

[mchollan]

According to my Haynes book the big bolt that holds the generator and starter clutch assembly should be torqued to ~110 ft/lbs.  I had a difficult time doing this myself because the hole thing wants to rotate as you apply torque.  I DO NOT RECOMMEND this, however I put a pry-bar (with a rag wrapped around the end) through one of the holes in the generator and wedged it into the engine housing to prevent it from rotating.  I was asking for trouble but it worked.  I think the correct way is to use an impact wrench or some sort of pulley isolator.

[adidasguy]

I stick an allen wrench in there where the starter gear meets the idler gear. Works great.

Some books suggest is to be in a high gear and hold the rear wheel.

There is a place for a thin 22mm wrench which is really what you should use to keep it from spinning.

[salamander]

Just my $0.02, but the service manual torques the mounting bolt to 79.5-94.5 ft-lb, with loctite recommended.  The '04 supplement says 87 ft-lb, which is in the middle of that range.

Don't know why Haynes says 110 ft-lb -- seems like a significant difference to me. 

[adidasguy]

Haynes is in NM, not FT/LB:  110-130 NM