UO
CHAPTER
FOUR
3.
Remove the starter idle gears
No.
I and
its
shaft
(
Figur
e
197
) from the crankcase. • ®
NOTE
71le
s/(Irter driven
gear
may
come
off
with
th
e alternator rotor
in
Step J or
Stlly
on the crankshaft.
4. If still
in
sta
ll
ed on the crankshaft. remove the
starter dri
ve
n gear (
Figure
198
) from the
crankshaft.
5.
If removed,
in
sta
ll
the starter driven gcar into
the backside
of
the alternator rotor.
6.
Try to rotate the Starler d
ri
ven gea r. It should
rotate freely in one direction and be locked up
in
the other direction.
7.
If the starter driven gcar will rotate
in
both
directions
or
is
locked up
in
both direction, replace
the starter clutch as described
in
this chapter.
8.
Inspect the starler gears (Figure
199
) f
or
wear
or
damage. Replace
if
necessar
y.
Insert the sha
ft
into its respective gear (
Figure
200) and rotate the
gear. Suzu
ki
does
not
provide speci
fi
cations for the
shafts nor the
in
side diameter of the gear
s.
If there
is a noticeable amount
of
play. rcplace the gears
and shafts
(F
igure
201
).
In
stallation
I. If removed. insta
ll
the starter driven gear into
the backside
of
the alternalOr rotor.
2.
In
sta
ll
the starter driven gear and alter
na
t
or
rot
or
assembly onto the cranks
ha
ft.
Tighten the
rotor bo
lt
as described under Allernator Rotor
R
emoval/
In
stallation
in
Chapter Eighl.
3.
I
ns
ta
ll
the
No.
I starter idle gea r and the long
shaft (43 mm) (
Figure
197
) into the crankcase.
4.
Po
sition the
No.2
starter
idl
e gear with the
shoulder side going on first and install the No
.2
starter idle gear and the short shaft (30 mm)
(
Figur
e
196
) into the crankcase.
5.
Insta
ll
the left-hand crankcase cover as
described in t
hi
s chapter.
Starter
Clut
ch
Replacement
1. If sti
ll
installed. remove the starter driven gear
from the backside of the alternator rotor.
2. Hold
Onto
the center
of
the rotor with a 36 mm
offset wrench.
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