Fixing a starter clutch that won't engage


Step-by-step tutorials on how to maintain and fix your GL1100
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tomos
Posts: 82
Joined: Mon Dec 23, 2013 7:00 pm
Location: GuelphOntario, Canada
Motorcycle: Gl1100 a 82
suzuki gs400e 82

Fixing a starter clutch that won't engage

Postby tomos » Tue Jul 28, 2015 8:58 pm



Hi every one,
Here is a solution for your starter clutch that refuse to engage even after you have tried all other remedies.
This is a problem that must be addressed ASAP.
Lines that you can see are actually worn out surface-deep chanels created by spinning rollers!!
You will need following :
- Impact wrench
-send paper 400 course
-rotary spinning tool
-rubber abrasive wheel 3/4 off an inch(should be available in rotary kit,green color )
-blue loocktite
-set of new rollers and springs ,Higly recommended!!!
At the end wash parts in a proper solution in order to remove any remaining course elements that can make damage.
Put loocktite inside not on the screws thread and add oil under screws head. Manually tighten screws as far as they will go,than take impact wrench and tight them all the way in.
Lubricate all passages and install rollers.
It worked for me and I am sure that you will be happy as well.
Attachments
Remove all screws using  impact wrench and proper screw removing attachment
Remove all screws using impact wrench and proper screw removing attachment
Deep chanels  visible,remove oil before  start sending.
Deep chanels visible,remove oil before start sending.
Deep chanels  visible .
Deep chanels visible .
Using send paper and straight  motion movement remove  all chanels
Using send paper and straight motion movement remove all chanels
Finished  product
Finished product
Using rotary tool and rubber wheel at 1000  rpm  get familiar  with  the  angles that you have to use in order to remove damage.DO NOT PUT BIG PRESSURE , JUST LIGHT TOUCH!!,once you get familiar  with process increase    speed to 3000 rpm and only LIGHT TOUCH AND CONSTANT MOVEMENT OF THE TOOL,you must not remove to much or roller  moving space will become to big and rollers  could  become  stuck again ! !!
Using rotary tool and rubber wheel at 1000 rpm get familiar with the angles that you have to use in order to remove damage.DO NOT PUT BIG PRESSURE , JUST LIGHT TOUCH!!,once you get familiar with process increase speed to 3000 rpm and only LIGHT TOUCH AND CONSTANT MOVEMENT OF THE TOOL,you must not remove to much or roller moving space will become to big and rollers could become stuck again ! !!
Final product
Final product



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