Gs500f starter clutch, ticking noise fix.

[Got2bnu]

I have a 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),( use as flywheel puller)put in hole of flywheel, tighten, bolt pushes against crank shaft and flywheel will pop 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 ( i think thats low so i did 25 lb)torque and flywheel bolt 110 lb torque, (again use locktite). Little under 3qt of 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]

When I bought mine that's the first thing I replaced.  The PO told me it was the starter, but from reading up on it I figured it was the starter clutch first.  When I pulled off the left covers I found that the three bolts had ripped out the threading on the generator (where the starter clutch bolts into).  If I can find it I'll upload pictures later.

I bought a used one from a wrecked bike at a local repair shop and I was running a few hours later....I wish.  Turned out there was much more wrong with the bike.  I won't tell the story because I don't want to hijack the thread but it was another 6 months before I was running.

Anyway, it seems the starter clutch bolts were a bit under-engineered on this bike.