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1981 GS 750 Suzuki - Counter Shaft Sprocket Repair

By Edited Nov 13, 2013 0 0

It was a great day for a ride, so I took the opportunity and got out on my 1981 GS 750 Suzuki Motorcycle. I ended up on a longer ride than planned, and when I stopped for a break, on the side of a country road, I realized I was out of gas. I didn't realize just how thirsty my bike was. Lucky for me a farmer across the road, was able to sell me some gas, and I got my bike running, but when I put it into gear, and let out the clutch, the bike didn't go anywhere.

I thought this to be odd, as there had been no sign of slippage prior to this ride. Thanks to CAA (Canadian Automobile Association) they helped get my 1981 GS 750 Suzuki home.

1981 GS 750 Suzuki - Counter Shaft Sprocket

Thinking I would have to pull the clutch apart, I took another good look at the

counter shaft sprocket (28433)
bike, and what made me think of the Counter Shaft Sprocket, was when I put the bike on the center stand and spun the back wheel. The chain was rubbing against the chain guard at the forward end and it had shown no signs of doing this before. It was easier to pull the counter shaft cover and have a look, than to take the clutch cover off.

Once I took the counter shaft cover off, I saw the shaft nut was loose, and thought it was an odd setup.

1981 GS 750 Suzuki - Counter Shaft Sprocket Repair

There is a plate on each side of the sprocket that is held with 3 screws. When I removed the sproc

counter shaft sprocket (28432)
ket cover, there was no sign of these 3 screws. The nut was laying in the cover when I removed it, and luckily the sprocket only slid off the splines, but didn't come right off the shaft.

It looks like the previous owner had stripped the nut that held the sprocket on the splines, that were lucky for me, in good shape. But I have no idea whether the nut was originally a lock nut, so I obtained a plain nut and torqued it to 60 foot pounds, drilled it and installed a cotter pin.

For the plate, I obtained 3 new screws, and installed them with Loctite. The original nut was counter bored to clear the splines, so I obtained a washer with a 25mm hole in it to do the same thing.

The washer was big enough to cover the screw heads and with using Loctite, these screws should not be able to back out.

To get replacement screws, I would have had to order a new sprocket assembly and there was nothing wrong with the old one on my GS 750 Suzuki. I decided to try a fastener supplier, and was able to get screws and all hardware required. (I used Brafasco as the supplier)

1981 GS 750 Suzuki

counter shaft sprocket (28431)

Bear in mind, when I first got this bike, I went over it for obvious running gear issues, brakes, suspension etc, and got the engine running and rode it to the shop for a safety inspection. The chain and sprocket appeared to be in good shape. Luckily, I didn't lose the chain and the sprocket didn't come through the side case.

If you need to do the same thing to your GS 750 Suzuki, be careful of the thread pitch on the metric hardware.

So, if you find yourself on the side of the road, unable to move, and you think it is the clutch, check the Counter Shaft Sprocket first. For more on this 1981 GS 750 Suzuki http://www.infobarrel.com/GS_750_Suzuki_1981_-_Re-Awakening_of_Rider_And_Bike


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