The engine rebuild for the 1981 Suzuki GS650L is starting to come together and the parts bin is starting to empty out. It is great to be able to get the original shop manual for a bike that is over 30 years old, but the photos taken during the tear down are invaluable. The old grainy, B&W photos of the 1981 service manual that were then probably and scanned to PDF are a little tough on the eyes.
Once the crankcases are back together, there are only a few big parts to reinstall before the lower end is pretty much complete. On the left side of the engine it is just the starter idle gear and rotor.
Before reinstalling the rotor, I did replace the 3 roller and spring assemblies of the starter clutch. Fairly cheap money to replace these components as the springs are barely more than you would find in a ball point pen. One of the original three springs was fully compressed in its slot, so it was probably a good time to take care of this upgrade.
The starter, gear position indicator, and stator will wait until the engine is back on the bike since most of these pieces are still connected to the wiring harness within the frame of the motorcycle.
The right side of the engine has a few more pieces that really start to bring the engine together. The oil pump and its gears, the gearshift shaft, the drive gear, and signal generator are all installed from the right side.
Oil pump and pump drive gears:
The primary drive gear, clutch sleeve hub, clutch plates, and pressure plate:
And finally the signal generator on the crankshaft:
Similar to the left side, the signal generator and clutch cover will go on once the engine is back in the frame.
The lower end of the engine is now operational. The crankshaft is connected to the drive gear and the transmission.
The parts bin is looking a lot better at this stage too:
More to do once the top end starts to come together, but I am thinking I will want to reinstall the engine to the frame before proceeding further. It is getting pretty heavy at this point.