Figuring Out the Clutch Shim

It seems to me that a lot of the clutch rattling issues on all these GS bikes were as a result of the clutch hub shifting laterally on the spline because the clutch hub and clutch hub spacer were of different dimensions.  In the later '83 and onwards GSX1100/GS1150 bikes, Suzuki addressed this by introducing a shim into the build that would remove the slack.  This shim came in 4 different sizes and is still available from Suzuki.  Here's how to measure the slack and dry build it: (click on images to enlarge)

On a flat surface, start with the oil pump gear and the bearing and spacer for it:

Put the clutch hub on top of this making sure the 2 notches on the oil pump gear fit into the appropriate holes in the clutch hub:

Then add the clutch spacer and bearing.

 At this point you will see that there is a lip here.  Where the clutch spacer does not end up flush with the clutch hub.

This is where the shim comes into play.

 Drop it into the middle.

 And put the thick washer on top.

 This is the gap you are measuring and it should be between 0.03 mm and 0.08 mm.

And again without the top washer.

Change the shim to ensure you are within the standard thrust clearance range.

Manna from Holland

I picked up a dustbin full of spares from Holland over the weekend.

Old Engine - Crank Comes Home

Got my crankshaft back.  I think I know what a glamour photographer feels like with a good looking model.  Isn't she a beauty?  (Click on images to enlarge).

This end was unwelded, taken apart and the inner bearing and rod replaced.  Then it was welded back up.

This is the new rod.

Both ends were subject to some drilling as part of the balancing process.

New rod.

New rod and drilled end.

The weld in here is the factory weld as it was not necessary to split the crank here.

All the big ends were replaced.

I love my new crank.  Don't really want to hide it away inside the cases!

Old Engine - Crank Goes for Repair

I decided not to give up on the old engine even though it makes no economic sense to spend more and more cash on it, I took the crank to an Old Skool Engineering guru.

This is the most wonderful workshop I have ever seen.  Crankshaft heaven.

 Below is the crank balancing equipment.

 Here is the man himself.  

It will take about 6 weeks.