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Starter Gear Upgrade '87 Cover Mod (Read 166 times)

savagebob

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Starter Gear Upgrade '87 Cover Mod
08/20/13 at 16:32:27

Hi All,

About to update the starter gear in my '87 to the torque limiter type.

I don't have a post '95 cover though so I'm going to have to mod my existing cover. I've read the technical document but just want to seek a bit more clarification on what is required.

Can anyone detail what I need to do exactly with my '97 cover to make it fit? Is it just drilling the hole a bit bigger?

chers

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Starter Gear Upgrade '87 Cover Mod Reply #1 - 08/20/13 at 17:12:59 not bigger deeper you need to Spot face the case deeper to accommodate the wider torque limiter gear.
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savagebob Full Member Offline SuzukiSavage.com Rocks! Posts: 235	Re: Starter Gear Upgrade '87 Cover Mod Reply #2 - 08/20/13 at 17:55:21 spot face? So just drill the hole a bit deeper that's all?
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savagebob Full Member Offline SuzukiSavage.com Rocks! Posts: 235	Re: Starter Gear Upgrade '87 Cover Mod Reply #3 - 09/03/13 at 00:30:06 so I've fitted the gears in for a trial fitment. Seems to just swap over fine but, the drive gear doesn't appear to cover all 3 of the rings of the torque limiter gear.. that can't be right can it?
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savagebob

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Re: Starter Gear Upgrade '87 Cover Mod
Reply #4 - 09/04/13 at 19:44:26

Ok from reading more threads apparently there are supposed to be 2 washers to go with the limiter gear? One on each side?

Anyone know the size of these washers?

Also, if I turn the idle gear and put in on backwards then it lines up, but all pics I've seen have it this way around (raised part facing out) does it matter which way around this goes?

thanks

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savagebob

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Re: Starter Gear Upgrade '87 Cover Mod
Reply #5 - 09/07/13 at 15:43:34

hmm this thread isn't very popular is it! Undecided

I've found that by reversing the idle gear, the alignment issue is solved. Does it matter which way around the idle gear is put?

The next potential problem is that the limiter gear doesn't sit flush with the flywheel. Especially with the washer installed as I've read that it needs. The teeth sit approximately half way on the flywheel teeth.

Is that a problem??

Standard gear alignment:

Limiter gear alignment

Someone must have an opinion on this?

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28657 Tucson Az Gender:	Re: Starter Gear Upgrade '87 Cover Mod Reply #6 - 09/07/13 at 18:07:49 Was the washer under the stock gear?... Maybe you don't need it...If the stock gear didn't have one,.. I think I might leave it out to get proper alignment... ... but, I've never done it...so, it's JMHO... ..(you definitely do need the outer washer)... fer' sure... yasser'ie...
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savagebob

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Re: Starter Gear Upgrade '87 Cover Mod
Reply #7 - 09/08/13 at 00:43:39

Even without the washer on the back the alignment on the flywheel isn't perfect, but, yeah it would be a bit better.

I read somewhere on here that the washers need to go because the gear has a toothed edge on both sides which I assume would eat into the alloy..

Maybe you don't need that washer there? Maybe the alignment with the flywheel doesn't matter? Someone here MUST know :'(

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Starter Gear Upgrade '87 Cover Mod Reply #8 - 09/08/13 at 00:52:29 you can get a thinner washer. the more the gears overlap the better. the teeth on the clutch are more likely to break. I'd make sure those fit the best.
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savagebob Full Member Offline SuzukiSavage.com Rocks! Posts: 235	Re: Starter Gear Upgrade '87 Cover Mod Reply #9 - 09/08/13 at 01:49:05 how thin are the washers that are supposed to be on there Verslagen? I can get the teeth on the idler and limiter gear to align nice if I turn the idle gear backwards is this an issue?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Starter Gear Upgrade '87 Cover Mod Reply #10 - 09/08/13 at 04:56:11 Wouldnt want the gear riding on the case. Need a washer to keep that from happening. There are some Mighty thin washers out there,,
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