Starter idle gear washer missing?

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  • Guest
    #1

    Starter idle gear washer missing?

    Hey all.

    I have finished rewinding a stator.

    photo 4.jpg

    Not bad if I say so myself.

    My bike is a 1983 GS1100GK.

    So I opened the LH cover to pull the dead one out.

    The shaft for the idle gear came with the cover. No big deal right?

    I removed the gear to make sure the washer that should be behind didn't move off centre or fell.


    There is no washer there.


    A quick check of diagram tells me that there should be one and that I ain't crazy.

    Part #3 http://cdn1.bikebandit-images.com/sc...su0062_012.gif

    So.....I can't find it in the general area.

    Probably went AWOL last time someone went in there right?

    I go to my Suzuki-Organ-Bank...Actually find the gear. Imagine that.

    There is no washer on the engine side of the gear........WTH?


    So this is my questions.


    Do some bike not have them?

    Can it hurt if I put one in (The sole survivor from the organ bank)?
    Like too thick or something like that?

    To me the aluminium where the gear as been rubbing for centuries is scoured in arcs. Light but not right.

    Opinions and comment?


    Daniel
    Tags: None
    • Grimly
      Forum Guru
      Past Site Supporter
      Super Site Supporter
      • Sep 2012
      • 5760
      • Ireland
      #2
      I'd say half the ones I've removed had one missing. The lack of them doesn't seem to have had any adverse consquenses, but I've endeavoured to replace them when possible. Careless POs or dealer servicing /repairs.
      Dave
      '79 GS850GN '80 GS850GT
      Only a dog knows why a motorcyclist sticks his head out of a car window

        Comment

        • hillsy
          Forum Sage
          • May 2008
          • 1469
          • Brisbane, Queensland, Australia
          #3
          Considering the gear only moves when you hit the starter then it's something that shouldn't be exposed to too much wear in it's lifetime.

          However, it's there for a reason.
          Current:
          Z1300A5 Locomotive (swapped my Intruder for it), GS450 Cafe Project (might never finish it....), XT500 Commuter (I know - it's a Yamaha :eek:)

          Past:
          VL1500 Intruder (swapped for Z1300), ZX9R Streetfighter (lets face it - too fast....), 1984 GSX750EF, 1984 GSX1100EF (AKA GS1150)
          And a bunch of other crap Yamahas....

            Comment

            • Guest
              #4
              Thanks Grimly.

              I expect you are exactly right.

              I will put it back with the second washer and call it a day. I am sure the wiggle room is there.
              Any secret to getting the gear in (Washer included) without removing the starter?

              I keep imagining the washer slipping off as I tilt the pin to get the gear in edgewise.
              I am imagining pasting it on with grease so it will stay put.

              Daniel

                Comment

                • Guest
                  #5
                  Originally posted by hillsy
                  Considering the gear only moves when you hit the starter then it's something that shouldn't be exposed to too much wear in it's lifetime.

                  However, it's there for a reason.
                  Yes, My bike proves it. I have had it for years (Exactly like that). But it's our bikes and when you know and can do something about it. Well we do. (The thought of steel rubbing against Aluminium is bad)

                  So I will,

                  Thanks,

                  Daniel

                    Comment

                    • Guest
                      #6
                      The GSX 400 doesn't show the washer and the ones I've taken apart didn't have one. I was tempted to use one anyway, but that would be assuming there was room for one. I'm not sure if the 450s have one either [same block].

                      There's no reason for a thrust load that I can think of. If you're worried about steel on aluminum then cam bearings must keep you awake at night. Along with pistons against cylinder walls and so on. Some engines use aluminum shell bearings on rods although the alloys are special. The marks that are there are probably from the initial machining which didn't have to be smooth because there isn't any load anyway; besides, the washer will be steel?...

                      If the gears were helically cut then it would be a 'whole nuther'.

                        Comment

                        • Brendan W
                          Forum Sage
                          Past Site Supporter
                          • Jul 2013
                          • 4920
                          • Wexford, Ireland
                          #7
                          Back one was missing on mine too. Replaced with two new washers and I'll swear it was quieter cranking
                          It might be worth fishing in behind the bottom of the clutch ring gear. They can get in there and lie flat in the space behind. You're working blind.
                          I eventually retrieved a washer with a magnet.
                          97 R1100R
                          Previous
                          80 GS850G, 79 Z400B, 85 R100RT, 80 Z650D, 76 CB200

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