Hi all, Long time lurker first time poster. Of course a question. First off, its an 04 500f. Bought the bike used, a few months back, bought it in an un rideable state from from orig owner. Not rideable from from sitting forever FYI. Bringing a bike back from the dead isnt my first rodeo so I knew what I was getting myself in for. Anyway, fast forward, bike is now running fantastic except for the starter clutch slipping. I had the clutch off and wanted to renew the springs behind the push pins, but, I cannot remove any of the three pins to get to the springs. I think I have diagnost the problem of the slipping clutch to these springs not putting enough tension on the solid rollers.. This is the first GS that I've owned and am not familiar to how far those pins that push on the solid rollers should protrude. Before I spend the dough and just replace the whole kit and kaboodle (tech term)....Does anyone have a shot of the internals of a function clutch or an Idea how I can get the pins and springs out without destroying them? Thanks all.
I had one or two of those pins sticking after I had the clutch apart and rollers out and just grabbed them with a needle nose pliers and pulled them out. Those springs just hold the rollers in close between the two wedging surfaces so the rollers can be grabbed when turning in one direction and can turn freely in the other direction. The springs don't add anything to the gripping power of the wedges on the roller. If the starter drive is slipping I'd first suspect the rotor was slipping on the crankshaft, not an uncommon problem on the GSs.
https://youtu.be/GxS5yZ44AHU
Over time those springs become tired and the rollers can develop flat spots.
Overhaul kits are available
http://www.wemoto.com/bikes/suzuki/gs_500_er/94/picture/starter_clutch_repair_kit/
Thanks guys.
For not much more that that overhaul kit you can buy a used working starter clutch off of ebay or a part-out on this forum. GS500 parts are so cheap, sometimes it just makes more sense to replace than repair.
Got the pins out...PIA btw. Polished the pins, cleaned out the guide channels and gave the springs a little boost by stretching them by a few mm. Probably didnt need to do that but they've been captive and compressed for a long time so what the heck.. Pins now move freely in the clutch and they all are putting pressure on the rollers now. No more slipping. Starts like I assume it did when it was new.. :cheers:
Hey Jack, Did I see in one of your posts that you are from Ohio? NE ohio here. :thumb:
NE Ohio here too, Madison.
Cool! Good work.