Here's some info I picked up from one of the other Hayabusa sites -
There is (as of this date)no recall on the busa starter clutches
The problem seems to occur under certain conditions,
(1)high heat-low battery charge;
(2)poor quaility gasoline;
(3) opening of the throttle while starting the engine;- make sure your fast idle levers adjusted correctly (mine wasn't so I was opening the throttle to start it - and I now have starter gear and clutch problems !!! and a now correctly adjusted fast idle lever)
(4)high compression(above 11:1)and/or big bore pistons
Suzuki Service Bulletin GS/GSX/GSX-R No 126 dated 12-10-02 shows the Interchange Info between the 03 and earlier models
The 03 starter clutches are not interchangeable with earlier models,
but the rest of the starter parts are,
if you want to buy a
03 starter motor,
03 starter idle gear limiter,
03 limiter pin,
03 starter clutch cover,
cap
and gasket
I have built 7 - 1397cc;13:1 CR; 395/378 cam and bored throttle body(48mm)engines to date
Each is using the stock starter motor and starter clutch
Starter mods include the heavy duty starter gear(APE) and GSTX12-BS battery with AWG 4 wiring from battery to starter relay to starter motor and AWG 4 cable from engine ground(at the starter motor) to the battery negative terminal
The stock wiring is IMHO to small to give full amps to the starter motor in high engine heat conditions,which cause the engine to spin over to slowly and invites the kick-back that causes the starter damage
Stock engines benefit from the wiring change and larger battery
Also,not opening the throttle when trying to start the engine in high engine heat coditions(stock or modified)greatly reduces/eliminates the chance of engine/starter kick-back
In my last post,I talked about using the Suzuki bulletin to replace the 1999-2002 starter parts with the 2003 parts
These are the part numbers:use p/n
12600-24F00 Limiter,starter idle gear to replace the earlier Gear,
starter idle No P/N 12615-24F00 pin to replace the earlier pin
The earlier idler gear bearing,2 flat washers and the wave washer are not used
P/N 31100-24F10 is the new starter motor needed to engage the limiter gear
P/N 11380-24F20 is the new Cover,starter clutch and is larger
P/N 11382-24F20 is the newer cap,starter idle gear
P/N 11491-24F01 is the newer Gasket,starter cover
P/N's 11492-24F00 Gasket;09280-33004 O-Ring; and 09166-16002 Gasket are all the same parts used from the earlier models
If your starter clutch is bad,use the new part 12600-24840 and do not install the K3 style starter clutch in a earlier model busa
The other tip I've picked up for the X to K2 starters is to slot the rear mounting holes which allows the gears to engage by an additional 3mm.
So to answer your original question, yes there are different covers.
Hope this helps.
Dave
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