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Old 12-05-2012, 09:08 PM   #71641
Chill
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Quote:
Originally Posted by opium89 View Post
Can someone tell me what function this bearing serves? This is the stator/generator cover......

I think (and this is a bit of a guess) that it is something to do with the starter motor. It lines up with the starter motor so I would presume that it supports the pinion gear that is driven by the starter.
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Old 12-05-2012, 09:19 PM   #71642
opium89
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Originally Posted by Davis53 View Post
I think it is the support bearing for the starter shaft and gear. Yes, you need it.
How is it going to support anything if the starter shaft is bigger on the outside diameter than the inside diameter of the bearing? It's either going to prevent the starter shaft from going in that slot on the cover, or it's going to run right up against the inside race of the bearing. This really isn't making much sense to me at the moment. The inside diameter of that bearing is just a hair under 12mm. The starter shaft is 14mm. Quite simply, it ain't gonna fit! I also just confirmed that the part numbers for a 1999 and 2000 are the same. Lists the bearing as 12x28x8.

Here's something that's a bit odd...the breakdown of the starter in the parts fiche shows that it has a bit of a tip....If the starter actually had that tip, and it was 12mm, the bearing would make perfect sense. In my case, the end of the starter is completely flat and ends at the splines...like so:






UPDATE: I just fitted the new bushing and starter clutch next the the starter shaft. The starter shaft doesn't even exceed the width of the clutch. My verdict is this bearing and clip are COMPLETELY unnecessary. Does anyone disagree?

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opium89 screwed with this post 12-05-2012 at 09:41 PM
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Old 12-05-2012, 09:34 PM   #71643
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Quote:
Originally Posted by opium89 View Post
This really isn't making much sense to me at the moment.
The bearing only applies to early models. I think 96 and 97. Early models had a starter with a longer shaft that was machined to fit the bearing. Somewhere along the way Suzuki apparently decided it wasn't needed. Current models have a short starter shaft but the cover still has an empty pocket machined for the bearing.
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Old 12-05-2012, 09:45 PM   #71644
opium89
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Originally Posted by procycle View Post
The bearing only applies to early models. I think 96 and 97. Early models had a starter with a longer shaft that was machined to fit the bearing. Somewhere along the way Suzuki apparently decided it wasn't needed. Current models have a short starter shaft but the cover still has an empty pocket machined for the bearing.
Makes more sense. I wish they would at least update the damn parts fiche. These parts all being special order and all. Oh well, what's $15.00 between (Suzuki dealers) friends, right? Thanks for the info.
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Old 12-05-2012, 10:11 PM   #71645
Adv Grifter
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Originally Posted by TrophyHunter View Post
Grifter - Did the adjustable Tusk handguard mounts fit your bars? I have tapered bars and the mounts won't fit around the "still tapering" section. They have mounts for larger bars but they don't have adjustment...plus it adds to the cost. I used some old large bar mounts I had laying around for the time being.

I like the adjustability of the standard Tusk mounts so I'll grind 'em out when I set time aside. I could use longer screws but the contact points 'tween the mount and the bar would be minimal.
I used my Dremel to make them fit. I did not have the Fat Bar Tusk kit so just ground out the standard kit a bit. You know most Bark busters never are a pristine fit on a tapering fat bar anyway. You have to kind of improvise it. Mine have been pretty good. Here is a pic:



Lots of adjustment.
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Old 12-06-2012, 03:20 AM   #71646
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Thx for the verification, Grifter. I'll keep grinding..... :)
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Old 12-06-2012, 04:10 AM   #71647
Emmbeedee
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Quote:
Originally Posted by procycle View Post
The bearing only applies to early models. I think 96 and 97. Early models had a starter with a longer shaft that was machined to fit the bearing. Somewhere along the way Suzuki apparently decided it wasn't needed. Current models have a short starter shaft but the cover still has an empty pocket machined for the bearing.
So, just for the record, if my 96 needs a starter, can I use the newer short shaft version?
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Old 12-06-2012, 05:28 AM   #71648
macrae85
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Tis a Galfer from Kientech; stops the DR like a champ...
Ta much!
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Old 12-06-2012, 09:31 AM   #71649
acesandeights
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Replacing bars - grips?

I am replacing my bars. Will I need to replace grips, or will the left one come off?
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Old 12-06-2012, 09:46 AM   #71650
mrprez
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Originally Posted by acesandeights View Post
I am replacing my bars. Will I need to replace grips, or will the left one come off?
I had to cut mine off.
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Old 12-06-2012, 09:51 AM   #71651
procycle
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Originally Posted by Emmbeedee View Post
So, just for the record, if my 96 needs a starter, can I use the newer short shaft version?
Dunno. I don't see why not but the long shaft with bearing support looks like a much more robust design. If I had to replace a starter I would seriously consider getting the old style and adding the support bearing.
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Old 12-06-2012, 10:42 AM   #71652
sunthechip
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I installed a new horn yesterday ( I haven't had a working one for at least 6 months), then I turned the power on and pressed the horn switch, but there was no sound, so I checked the electrical connectivity.
When I bypassed the switch with a screwdriver the multimeter would read 13V where the horn plugs in, so the switch was the problem.....

I dissembled the entire left hand control and cleaned the inside of the horn switch with a pipe cleaner, turned the power on, pressed the horn switch, and the multimeter read 13V.

I thought it was all fixed, so I reassembled the control unit to the handle bar, turned the power on and pressed the switch to see if it was working properly ........NOPE.

So then I disassembled the entire control unit AGAIN to figure out why the switch wasn’t making contact.

It turns out the horn switch was not flush with the plastic exterior of the control unit, so I wedged a piece of a zip-tie in the crevice and brought the crooked end of the horn switch forward and flush.

I reassembled the unit (halfway this time) and tested the switch... BINGO, 13V on the multimeter.

2 hours later everything works and the horn fires up nicely...
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Old 12-06-2012, 10:45 AM   #71653
Emmbeedee
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Quote:
Originally Posted by procycle View Post
Dunno. I don't see why not but the long shaft with bearing support looks like a much more robust design. If I had to replace a starter I would seriously consider getting the old style and adding the support bearing.
Good point - newer is not necessarily better.
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Old 12-06-2012, 02:09 PM   #71654
Rusty Rocket
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Quote:
Originally Posted by procycle View Post
Dunno. I don't see why not but the long shaft with bearing support looks like a much more robust design. If I had to replace a starter I would seriously consider getting the old style and adding the support bearing.
It's a superceded part #

http://www.ronayers.com/Fiche/TypeID...STARTING_MOTOR

and the shorty is the only one avail. Sell you a collector's item outta my '96.
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Old 12-06-2012, 02:43 PM   #71655
procycle
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Quote:
Originally Posted by Rusty Rocket View Post
It's a superceded part #

http://www.ronayers.com/Fiche/TypeID...STARTING_MOTOR

and the shorty is the only one avail. Sell you a collector's item outta my '96.
The long shaft starter is still used in their ATVs. It's available from several aftermarket suppliers.
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