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Message started by trickbikeman on 06/15/05 at 16:48:25

Title: startergearassembley
Post by trickbikeman on 06/15/05 at 16:48:25

I need a manual that showsthe entire moter repair my starter broke the gears that turn the moter plus part of my case I might be better off getting a whole knew moter I would rather fix it but I dont know how thats why I need the whole moter manual where can I get 1 ?????????

Title: Re: startergearassembley
Post by bobo383 on 06/15/05 at 18:41:38

If it's pics you need, RonAyers.com has good ones on the online fiche:

Savage starter clutch pic on RonAyers: http://www.ronayers.com/fiche/300_0271/starter_clutch/starter_clutch.cfm?man=su&groupid=7190&parent=7080

Bike Bandit is the same pic, but not as easy to see for some reason.

You can find Clymer manuals and engine parts (case) on ebay, but you may have tried both of those already.

Hope this helps.

Title: Re: startergearassembley
Post by red2k1 on 06/17/05 at 04:09:33

Here is a site for the "official" Suzuki Manual: http://www.repairmanual.com/catalog/99500-36085-03E

Sometimes, you can find this manual on eBay a lot cheaper.

Title: Re: startergearassembley
Post by Derek on 06/18/05 at 16:58:27

Hey trickbikedude, not to worry. Allow me to make a contribution to this forum. I have heard of a couple other Savages with the same problem. Your repair is very do-able. I bought my '86 this year with the same problem. I can walk you through the repair, and without taking the engine off the bike. First, get the manual and you'll need new/used parts to replace those broken ones: idler gears, pins, starter clutch assembly, gasket, etc. There is enough thickness in the left side crankcase wall to drill out a smaller diameter hole about 1/4" deeper than original to sit the new idler gear pin into and simply turn the new/old pin on a lathe to make the end 1/4" the same diameter as the drill bit you use. It will be stronger than original and will save your engine. Make sure you cover over the lower oil passages with rags or the drilled materials will end up in your crankcase...not a good thing. If you need more details of my repair job, let me know. It does not take long and the job is holding fine.