Engine Knock

[stuiec]

Ok, been awhile, but I finally got to this issue. I took the clutch apart and inspected everything, all was within spec. I serviced the cam chain tensioner, seems good too. So now I'm headed for the starter clutch. When I had it running, doing the block of wood-stethoscope method, the sound was loudest on the left side, near and on the generator cover. Here is what I am seeing so far......is this gear supposed to have this much play? (click for video)

[stuiec]

....bump....

[tkent02]

It's not supposed to wobble like that.

[posplayr]

Looks like someone might have left out some parts.

[GSX1000E]

I believe that you found the source of that odd knocking sound.

http://www.partsoutlaw.com/oemparts/...starter-clutch

http://www.partsoutlaw.com/oemparts/...cb0d/generator

[stuiec]

Thanks guys, I'll pull the flywheel and have a look. Which leads me to my next question, and again, I have been searching the forum, just can't narrow it down. In the shop manual for this bike, I'm told to use the -suzuki parts # here- special tool, in this case, a slide hammer inserted into the other suzuki tool that threads onto the male (I measured 30mm), thread on the outside of the hub of the flywheel.

Nobody here seems to be posting about using this method, but I cannot whittle it down to a decisive option to go another way, as I haven't found anyone doing the same thing to the same model bike. Peering down the bore through the flywheel, it appears to me that there is no change in thread diameter or pitch, all the way down to where things taper in to a point in the end of the crank-shaft.

[GSX1000E]

MotionPro makes many of those tools but some of these models only need a bolt that goes in the center to pop the rotor off. Not sure about your model.

[stuiec]

MotionPro makes many of those tools but some of these models only need a bolt that goes in the center to pop the rotor off. Not sure about your model.

That's what I've found. Correct me if I'm wrong, but all I need when ordering one, is the diameter of the male thread, and the diameter of the inside thread + length? I'm just a little wishy washy about it being that I've read that alot of guys end up with the wrong size.

[stuiec]

If I can find a good post or diagram of what my model looks like through that bore, I'd be set.

[Big T]

Is there a factory service manual for your bike on BassCliff's site?

[blowerbike]

your rotor should push off with a bolt as i assume you have a bolt that has to be removed to let you see the threads in the rotor itself.
this as apposed to a nut having to be removed as on large GS models.
FYI
the smaller GS's are not prone to starter clutch failures and there should be some side movement in the large gear as it only turns when you start your engine.

[posplayr]

That's what I've found. Correct me if I'm wrong, but all I need when ordering one, is the diameter of the male thread, and the diameter of the inside thread + length? I'm just a little wishy washy about it being that I've read that alot of guys end up with the wrong size.

On some bikes like the 81 gs750e the swing arm bolt will work

[stuiec]

Is there a factory service manual for your bike on BassCliff's site?

There is, and I'm using it, thanks.

your rotor should push off with a bolt as i assume you have a bolt that has to be removed to let you see the threads in the rotor itself.
this as apposed to a nut having to be removed as on large GS models.
FYI
the smaller GS's are not prone to starter clutch failures and there should be some side movement in the large gear as it only turns when you start your engine.

It is a bolt, and I have removed it already. From what I've read of other models, the threaded portion of the crankshaft is a smaller diameter than the threaded portion of the rotor. It does not look like it is in my case.

Is there anywhere I might find a spec on how much side to side movement the large gear ought to have? It does not seem worn out, it slides cleanly on the shaft without wobble.

On some bikes like the 81 gs750e the swing arm bolt will work

I'll check this out, thanks.

[blowerbike]

is there threads inside your rotor from where your removed your crank bolt?
take your crank bolt and drag it through the hole(off set) and see if it catches threads...
click click click you know what i mean?

[stuiec]

ok, I finally got my flywheel off, and here is what I found...