OK This is second starter clutch I am swapping on a GS ... not the same GS, different GSes. First one had a lot of bite marks on its engaging gear and some flat spots on the rollers ... OK I can imagine why ... of course that I ignored for 6+ months and ended up with goats ...
This bike ... it make that klunk on hitting the start button - twice ... I decided to swap the thing ... and I see that there is some light bite marks on the engaging gear, and of the 3 springs in the thing 2 are bent or broken ... So ... my question is ... can that make the clunk noise or is even light marks on the engaging gear bad enough to replace.
Then I tightened the crank nut to ~90 lbs and ended up with a engaging gear that almost was binding in spots - That binding might cause starwalts ... So I loosened it and set it back to ~75 and its free wheeling one direction and engaging the right way ... So anyone know what that means ... and is the thing supposed to shake/slide just a little ... just barely perceptible movement ...
Cool.
Srinath.

Quote from: seshadri_srinathOK This is second starter clutch I am swapping on a GS ... not the same GS, different GSes. First one had a lot of bite marks on its engaging gear and some flat spots on the rollers ... OK I can imagine why ... of course that I ignored for 6+ months and ended up with goats ...
This bike ... it make that klunk on hitting the start button - twice ... I decided to swap the thing ... and I see that there is some light bite marks on the engaging gear, and of the 3 springs in the thing 2 are bent or broken ... So ... my question is ... can that make the clunk noise or is even light marks on the engaging gear bad enough to replace.
Then I tightened the crank nut to ~90 lbs and ended up with a engaging gear that almost was binding in spots - That binding might cause starwalts ... So I loosened it and set it back to ~75 and its free wheeling one direction and engaging the right way ... So anyone know what that means ... and is the thing supposed to shake/slide just a little ... just barely perceptible movement ...
Cool.
Srinath.

mine had light wear marks.  Make sure the oil hole thing is aligned right on the gear behind the magnet.. maybe...

Clymer specifies 43.5-to-50.5 ft lbs for the rotor bolt.  Apparently, you overtorqued to double value.  The starter gear must have end play otherwise it will spin itself, the idle gear, and maybe even the starter at engine speed.       That's likely to be the event which marked the gear teeth and took-out the springs.  

Clymer says what ... Suzuki manual said 79 to 95 lbs I believe ...
The springs were broken, but the gear spun free before I pulled it, it wasn't binding ... After replacing it is what my question was for.
Cool.
Srinath.