clunk noise @ start up

[Srinath]

Mine I am almost certain is left side. And almost certainly like the starter clutch issue on my GS500 I had a few years ago.
Can the woodruff key on the left side cause that same issue ?
Cool.
Srinath.

[hb7]

This is the problem I have

That looks repairable to me.
I would weld that stronger than it was before, and machine it back into service........

[Bill Jurgenson]

no, because the flywheel is on a taper and once drawn up tight, it will not move. If the flywheel has never been pulled, it is quite an ordeal to pull it and is only possible with serious tools for the purpose. The small key on that side is only for orientation.
Such keys should always be only for orientation.
The primary and balancer gears sit on a cylindrical shaft and are entirely dependent on the clamping force of the nut and the 6mm(!) square key. It is this key that is usually sheered off, not that of the balance shaft itself.

The starter clutch can make noise; all of mine have and my SZR is no exception. It is not a problem and does not warrant attention unless the flywheel has to come off anyway.


BTW, the two keyways of the crank and balancer face each other when correctly lined up; don't need to depend on markings at all. The original gears have a centerpunch dimple; so does that alternative gear from the Raptor but not in the same place since the Raptor has a different setup with two balancers.

[Srinath]

OK the flywheel - I should check if it is indeed tight. However I wont say it doesn't need to be checked if it makes a clunk. How much of a clunk is normal for this bike is the real question. My only other singles - the savage used to clunk too, but it was very much softer than this. Anyway my GS500 used to clunk when you hit the starter ... and I ignored it. Its starter clutch had gone bad and I should have fixed it, but I didn't. The year or so that I rode it without fixing it caused the alternator rotor which is bolted to that gear that the starter meshes to, come apart. Anyway I will look over this bike and make sure my clunk noise is on the left and ignore it if it can be. I guess I better know this bike as well as I know the GS500.
Cool.
Srinath.

[Srinath]

I had a question about this clunk noise -
If it was comming from the clutch basket drive gear on the right side wont it make that clunk noise whenever you shut the throttle ?
I only get the noise when the motor is likely to be turning backwards. As in I shut it off when its on the way up on compression stroke, or when I am starting and let go of the starter button ... likely when the compression stroke is happenign and by letting go of the starter it closes the decompressor and there it cant go on compressing and it spins back ...
Cool.
Srinath.

[hb7]

Post up an audio file.......let's hear it.

[Srinath]

I will try, its scheduled to be picked up by my very very handy and mechanical friend - who actually works as a mechanic instead of a software engineer like me, so I may not get to it in a while, If ever.
Cool.
Srinath.

[spadesup420]

This is the problem I have

That looks repairable to me.
I would weld that stronger than it was before, and machine it back into service........

im gonna try i finally got the socket that will fit the crank nut so now i will finally get the crank case split and make sure there is no more damage i will post more pics in my thread

[Srinath]

I am near about sure mine is on the left side and from the crank area, right behind the center plastic round cover, not the starter part.

If the starter clutch on this motor is starting to go, what sorta noise would that make.

BTW the starter clutch in this is the 100 internal tooth biting on the center hub type that is on the katana 600, savage 650 etc in bikes I have split open.

AFAIK on these suzuki's I have never seen one of these go. The savage has a unique design "feature" that will allow it to shear off all the teeth on the gear and break the idlers out of their pivots and splatter the guts of the gears nice and good into the motor ... but that 100 teeth contraption will not give up. Matter of fact I have one of those sitting round I may try it on for size if it would do anything.

Cool.
Srinath.

[cat]

After reading the various threads on this (google site:www.mzriders.com balancer gear key),...

- Is the Raptor 700 balancer gear thicker than the XT600E gear, so that the washer/s are not needed?

- Should the face of the gear on the shaft be exactly flush with the step on the shaft that the nut tightens against? (Do the washer/s space it out so that it is?)

- Where to get shim washers, if using the XT600E gear (or the Raptor gear and it is not quite thick enough)?

[edfmaniac]

Do a search for "washer" and scroll down to the "Single carb mod" thread.

"Remove all parts including the thick soft steel washer behind the thin retainer washer of the OEM balancer gear; the Raptor gear is that much thicker."

Sounds like it gets removed.

[Srinath]

The raptor 01-03 starter clutch I bought does not fit. The inner dia of the 660 is too large and the bolt circle of the skorpion is too small. Not a fit at all, pity too, that part was absolutely beefy and looked like it would've worked too.
Anyway I put it back together with the old parts, my issue is that its not starting. I'll deal with the clunking once I get it to start.
Cool.
Srinath.

[Cerver]

Post up an audio file.......let's car navigation system hear it.

I think there is no audio file till now. Have you got any?