I got a sweet deal 2004 suzuki gs500f, but the catch was that it did not start. So I went on to find what was wrong. I tried starting the engine but could only hear the starter motor turning. I pinpointed the problem to the starter clutch bolts. I will list the process of fixing the starter clutch below.
Inspect the old starter clutch components. The springs,rollers, and the pins. If any of them are damaged replace them.
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Oil resistant locktite
7/8 thin wrench
Clutch fly wheel extraction bolt 1.50 thread atleast 1.5inch in length
Allen wrench keys
Disassemble the fairings using allen keys. Take off the shift lever (10mm) bolt. Remove all of the 8mm bolts on the chain and magneto cover. Remove both covers.
Use the 7/8 wrench on the shaft and 22mm wrench on the flywheel bolt. We shaved off the wrench ending so it would be thinner and fit. Also hear up the end of the wrench and bend it.
Remove the stator(magneto) and remove the allen bolts.
Suzuki Gs500f 2004
Inspect the rollers,springs, and pins. Replace if nessesary.
Drill new holes in the stator housing.
Cut new threads.
Use oil risistant locktite on the three bolts tighten to torque spec. We decided to weld the bolts aswell so they wont come loose.
Use oil risistant locktite on all main clutch bolt and tighten to torque spec(87lbs-ft). Reassemble and top off engine oil.
2015 Suzuki Gs500f Manual Parts