Suzuki 2 Strokes

Hi Guys. I am elbow deep in replacing the starter clutch on my '75 GT550. I am having a little trouble determining exactly how many of each thrust washers I need. The service bulletin says on one page I need the stock 08211-22503 plus an additional 09160-23005 between the basket and the driven hub. on another page the bulletin only shows to re-use the stock 08211-22503 between the basket and the hub. So I am not sure what to use there.

Also do I need a thrust washer between the starter clutch gear and the case/transmission bearing? I think there was one in that spot when all of the pieces of the old style clutch fell out all over the place.

Thanks
Jason

As depicted here http://www.3cyl.com/bulletins/index.html (GT26) you need to use the old washer and the new one together. What happens if one is ommited is the whole assembly will take up completly and bind up and the engine will not turn over. Been there - done that!
Assemble exactly as shown on page 2 and add the extra washer 09160-23005 between #1 and #2. Look at all the pages because things need to face a certain way.

I don't mean to dredge up an old topic here, but I'm going through this "process" of putting a new starter clutch in right now.

When I took the one that is in my 1974 GT550 out, I found that it had already been converted to the new starter clutch. I only had ONE thrust washer between the clutch sleeve and the basket/primary gear assembly.

It's seeming to me that Coyote is saying in this thread that you need two washers there The replacement assembly I got, only had ONE washer in that place too, just like the diagram on page 2 of the bulletin. I could be reading things wrong, but it's seeming to me that page 3 talks about using that additional washer when you are using the "new style" clutch sleeve that is either flat or hollowed out on the side facing the basket with the old style primary driven gear (basket). Both of the clutch sleeves I have are the "old style" that have the protrusion in that area. So, adding that additional washer in my case seems to be overkill.

I guess I'm just confused.

The use of the extra spacer/washer depends on which new sleeve hub you are using as the design changed and there are two different new ones. Check page three at the link Coyote provided - if it is the one with a flat face it isn't required, if it has the recess then you need it.

Mine are the "old style" and have the protrusion....so I'm going to just keep using the one thrust washer like I have been.

Thanks!

If I were you, I would take one of those clutch baskets to a machine shop and have them face it off flat. Mine definatly took 2 washers. I tried to assemble with just one, but that end bound everything and the motor would not turn over. The additional washer cured that problem.