Starter Clutch?

[Suzkuz]

Bike= 86 suzuki gs550

My problem started with my starter only cranking very weak, as if it wasn't getting enough current/voltage. So I decided to take the starter out and examine it to see if I could find the problem. After getting it out and taking it apart I saw that the contacts that the brushes meet with were very dirty, so I cleaned them and every other electrical surface inside of it.

I put it all back together and after laboring with getting the carbs back on I finally got everything in place. I hit the starter and heard only the rotating of gears down by the starter, no crankshaft movement at all. I took off the side cover and saw this while cranking it:



When I rotate the crank by hand (via the bolt in the lower left of the picture) it will turn the starter gears in the same direction as shown and turn the crank. Its just that when I use the starter to crank it the gear spins freely.

So I assume the problem is with the starter clutch, and I have no idea how to go about checking it out. It looks to me that it is sandwiched between the large starter gear and the alternator housing, but that is only a guess, and I don't know how to get the housing off the check.

So I'm hoping someone can give me some insight on where to go from here. Thanks for any input.

[Aussie Steve]

If it spun the crankshaft before you pulled it apart then I suspect something was put back incorrectly. Having said that the weak cranking may have been something to do with the clutch but I suspect a weak battery and or connections.

If a clutch is going to play up it usually slips and if that were the case your starter would have spun even faster. As for pulling the clutch centre my book for a B12 states a special tool is needed to lock the whole assembly so the centre nut can be removed.

I would tend to think a special tool can be manufactured to do the same without going to the expense of buying one. Disassembly will probably be similar in most cases but a manual is probably the least you will have to buy.

Good Luck. Good pics too!

[Suzkuz]

Before I took everything apart I made sure that it was getting enough power, I bypassed the solenoid and everything, and still got a very weak wine that lasted only a second or two out of the starter.

Now the only thing I can think of that would explain this other then the starter clutch being shot would be that I somehow managed to make the starter spin in the opposite direction. Can anyone confirm that the starter is spinning the correct way (clockwise)?

[Aussie Steve]

Just drop the bike in gear...third or fourth and roll it foward to check the rotation of the crank. If it rotates clockwise then you are correct. As to the starter motor giving a weak wining sound I reckon the problem is the starter motor. Try a direct cable connection from the battery to check the motor.

You stated that when pulled the motor apart there was a lot of dirt where the brushes meet the contact...not too sure what you mean by contact... but generally if there is a lot of carbon around the brushes will need replacing. The weak cranking could be due to the brushes not being pressed onto the armature tightly enough because they are too short.

Other points could be the kill switch...believe it or not a lot of people have had problems with them and no longer use them....myself included...and any safety switches...ie clutch lever and/or gear lever... if fitted but usually you do not get anything if these are playing up.

For what it is worth I would put my money on it being the starter motor brushes being worn out. They should be fairly cheap and you can always use some for a power tool if not. Some reshaping may be necessesary.

[david599]

Are you sure the battery doesn't need replacing?

[Blade]

The starter gear should spin free in one direction and not the other. Also make sure the starter is spining and in the right direction when you hit the button.

If everything is doing as above them make sure that the starter is spining the gears in the correct gears in the correct direction.