Suzuki 2 Strokes

Hi there.. My 550 has had a bad starter clutch this summer... Starter motor runs perfect at the push of the button but most of the time it just spins. Without engaging with the crank. When it does "grab" the crank, after 5 attempts on the button, it only spibs it for 1 second, the spins again.

I thought ' no problem' took the clutch cover off, and took the entire clutch basket incl. Starter clutch from my spare engine, but this is the same! Only pulling the crank every 5 attempts and only for 1 second.

The starter clutch on both engines is the new type with 20 small ' pawls' ... How do I fix it??

Never known problems with the later Borg Warner type. have a look at the centre that the starter clutch grabs to see if there's a problem with it or something on the clutch centre rear part.
Seems strange that both your starter clutches have the same problem.

Will check it out... Before i rebuild the engine it worked pretty well. But hard to see what could go wrong.

I have both the clymer and haynes manuals, but they dont show assembly of the new type starter clutch

The upgraded starter clutch is covered by service bulletin GT-26:
http://www.ozebook.com/compendium/techb ... 022-26.pdf

What oil are you using? I had the same problem after switching to synthetic!
Also, drain the oil and check for any metal fillings. The starter clutch won't hold if there is a lot of metal in the oil!

Cliff wrote:What oil are you using? I had the same problem after switching to synthetic!
Also, drain the oil and check for any metal fillings. The starter clutch won't hold if there is a lot of metal in the oil!

I really not sure if that oil is synthetic... Dont have the can anymore. But it was proper gearoil for 2-strokes though.. Did it help yours with changing oil? And what oil did you use?

All parts looks fine

I used Duckhams 20w50 back in the day and worked fine. Same stuff goes in the forks to stiffen up the damping too. Recommended to me by Crooks Suzuki, and they did (still do) know what they're on about having raced them since the early 60s.

I took the starter clutch apart today... When i removed the borg warner one way, 3 of those small claws fell out of the bearing... The small thin piece of metal/brass spring was missing holding these 3 claws. I cleaned all the parts and put it all together again without the 3 claws and "grabs" instantly again. Keeps holding as long as i touch the starter button.. But my donor clutch still doesent work. I will put in the original starter without the 3 claws and hope it will work properly...