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Message started by blackiex on 06/16/06 at 16:29:54

Title: Starter clutch stucks
Post by blackiex on 06/16/06 at 16:29:54

Dear Savage gurus,

My 1994' beauty behaves strange for a while. Battery fully charged, petcock open, fuel OK, spark OK. It should start, but it won't, because my starter motor does something wrong. It spins a bit, the engine rotates a few times, then is gives a "clank" noise and stops turning. Releasing and pushing the starter button again, the strarter clanks again without rotating a bit. I used to 'release" the stuck starter clutch by pushing the bike backwards a few inches in 2nd gear and it worked, after that it crnaked again. Today this method failed. I guess I have to check up the starter system, but I have no idea what could be the problem or how to solve it.

Any advices would be appreciated. Thanks in advance!

David, Hungary

Title: Re: Starter clutch stucks
Post by Reelthing on 06/16/06 at 19:15:48

before you dig deep - make real sure the battery is hold the charge it should be - after it's been sitting over nite with out a charger on it measure the voltage with a digital volt meter - is it 12.7 or more?

Title: Re: Starter clutch stucks
Post by Keith_B on 06/16/06 at 20:34:53

Also check the compression releaf to make sure it is working right!

Title: Re: Starter clutch stucks
Post by thumperclone on 06/16/06 at 23:12:34

is the battery a 94 also?? check starter wire for tight connection also..

Title: Re: Starter clutch stucks
Post by azjay on 06/17/06 at 06:32:32

batteries can get to point, where they appear to hold 12v, but cannot deliver under load. a digital multimeter on the battery while starting should read better than 11v. as mentioned, check battery connections for corsion, tightness, and check the cables to make sure corosion hasn't crawled into them. good luck

Title: Re: Starter clutch stucks
Post by blackiex on 06/19/06 at 23:27:20

Well, I bought a new battery this morning. After arriving home I checked the voltage, my multimeter shows 12,4. What if the charging circuit is defected? How should I check it out?

Thank you!

Title: Re: Starter clutch stucks
Post by Reelthing on 06/20/06 at 04:49:04

you were 12.4 on the new one or the old one?

Title: Re: Starter clutch stucks
Post by Savage_Rob on 06/20/06 at 06:48:19

Reelthing wrote:

you were 12.4 on the new one or the old one?

...and does she start with the new battery or are the results the same as your original post?

Title: Re: Starter clutch stucks
Post by blackiex on 06/20/06 at 13:34:17

It is the new battery that gives 12.4. The bike starts up normally. The failure of the charging circuit will be obvious if it won't start a few days later...

Title: Re: Starter clutch stucks
Post by Reelthing on 06/21/06 at 14:59:58

12.4 is not very good for new battery - at 12.2-12.3 the engine will turn but the ign will not fire - to check for charge leave the multimeter hooked when you start the volts will head up

let's add this to the list - 12.27v will not start an '02

http://suzukisavage.com/cgi-bin/YaBB.pl?board=RubberSideDown;action=display;num=1138061012;start=

Title: Re: Starter clutch stucks
Post by blackiex on 07/01/06 at 16:02:35

Well, guys... My Savage ain't got any charge and that is for sure. As you know, I bought a new battery (BigCrank is not sold in my country). After a week or two it can't even crank the engine, so that means that there is no charge. What do you suggest I should check? How should I know whether the alternator gives any voltage to my battery?

Tnaks in advance!

Title: Re: Starter clutch stucks
Post by diesel on 07/01/06 at 22:27:38

attach a volt meter to a known good battery(one that withstands a load test) fire 'er up, being rpm up to 'bout shift point, volt meter should read minium, 13.8 to max of 14.8 volts. that'll keep most batterys at full charge.

Title: Re: Starter clutch stucks
Post by blackiex on 07/04/06 at 10:18:36

I tried what you suggested, diesel. My electric system is in critical state. The voltmeter reads 12.25-12,6 from idle to shift point and it comes much worse when the headlight is on. Only 11,6-11,8. The wires that come from the generator into the regulator (three yellow) and the black-white cable that comes from the regulator are HOT! If I disconnect the connector from the regulator with the red, black-white and orange-black cables the voltmeter reads almost 17 volts betveen the black-white and the red cables.

Shown on this picture:
http://chopperfield.uw.hu/hot_cables.jpg

Title: Re: Starter clutch stucks
Post by diesel on 07/04/06 at 22:21:19

IF the alt. can produce that kind of voltage with out control, don't think rotor, brushes, or stator at fault. if possible, try a known good reg,-rec. kinda difficult to trouble shoot, not being there. automotive alt. with external regs. could be put into an uncontroled out put by disconeting reg. and hot wiring alt. field. don't understand how you got an uncontroled output by just disconecting the reg. mabey sombody here could 'splain that to me. the 3 yellow wires comming the stator should show no continuity to each other or to ground, that would indicate a bad stator, if you put a ac volt meter on each yellow wire to ground with engine reved , each wire should show close to 75 acv. thats what they would show on a 1000, 1100, or 1200 honda wing, manual for LS should have those specs. just trying to be a little helpful if i can. diesel

Title: Re: Starter clutch stucks
Post by blackiex on 07/05/06 at 00:51:47

The yellow cables show continuity to the ground. According to the wiring diagram, the coils in the strator are bonded together radially (like a Y) and I guess their central terminals are connected to the ground. Like on this picture... I think the red arrow shows the point where the ground is connected to the colis. Like in high voltage generators.

http://chopperfield.uw.hu/generator.jpg

Title: Re: Starter clutch stucks
Post by klx650sm2002 on 07/05/06 at 03:06:12

The KLX battery (YTZ12S) has only 12.44v but starts her in 3-5 seconds.

Clive W :D

Title: Re: Starter clutch stucks
Post by Kropatchek on 07/05/06 at 08:10:47

blackiex wrote:

The reading in Ohms between the yellow wires from the alternator should read between 0.52 and 0.78 .

The AC output between the same yellow wires are 100 volts+ at 5000 RPM

Regulator output at 5000 RPM 14 - 15.5 volts, measured over the connected battery.

All this figures from the Suzuki Workshop Manual.

Suggest you get one or a Clymer WSM , there's several on offer at E-bay.

Greetz
Kropatchek 8)

Title: Re: Starter clutch stucks
Post by blackiex on 07/06/06 at 10:49:10

I guess I have solved the problem. The connectors were dead, that's why it was hot. I cut them off and replaced them with these connectors. They are for 220/400 VAC, but they were cheap and easy to assemble. :)

Thank you for your help!

http://www.procontrol.hu/ALKATRESZ/Elektromechanikus/Sorkapcsok/et1103sz.JPG