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Message started by Psycobilly on 10/19/07 at 19:43:28

Title: Trashed case?
Post by Psycobilly on 10/19/07 at 19:43:28

Hello, I just joined yesterday. I bought a Savage from a kid, who just left this bike out in the yard for about a year. Well, he must have had the idea that taking everything apart would fix it, because that's just what he did. Well, the original story, was it wouldn't start.

Well, I pulled the case cover on the left (drive) side, and found the problem. I am new but will try to describe it the best I can. As the starter gear comes through, there were two gears between the starter, and flywheel? These two gears are busted out of the case, and took a great chunk of aluminum, with them. I figure there are also 10-12 teeth missing on the flywheel.

I will try to post a few pics, so we can evaluate, but for now, that's all I have. A good newbie explination. :-/

Title: Re: Trashed case?
Post by Savage_Greg on 10/20/07 at 06:47:47

Sounds like a real foobar. How did the kid do that? Was it a "floating washer" problem?

Title: Re: Trashed case?
Post by Psycobilly on 10/20/07 at 07:05:00

I dunno, what a floating washer is. I guess ignorance is bliss. The first thing is, I wish I knew how it happened, as not to repeat that mistake, as I have no experience with an electric start.

The bike sat up for about five years. Maybe no lube. I could see that happening. I guess when it let loose, it tore out those gears, and then the starter just ginned. Maybe thats why he couldn't get it to fire.

Of course the main point is I'm gonna need a case. The damage is beyond my capability to repair. I will dig out the digital camera today and post the damage.

Title: Re: Trashed case?
Post by Savage_Greg on 10/20/07 at 08:12:08

Psycobilly wrote:

Is it the outside case or the crankcase that is broken? Is the case broken around the 2 (same size) starter gears?

Title: Re: Trashed case?
Post by Psycobilly on 10/20/07 at 08:58:39

Yes, the crankcase is where the two gears came loose, but there is no visible damage to the crankcase cover. I'm getting pictures now, so I'll get them posted shortly.

Title: Re: Trashed case?
Post by Savage_Greg on 10/20/07 at 09:06:55

Psycobilly wrote:

Yes, the crankcase is where the two gears came loose, but there is no visible damage to the crankcase cover. I'm getting pictures now, so I'll get them posted shortly.

So far, this ain't sounding good ::)

Title: Re: Trashed case?
Post by Psycobilly on 10/20/07 at 09:20:38

Yeah, It ain't looking good either. Still waiting on the camera phone to email me, but I have a good picture of the mess

How available are cases, while I'm waiting?

Title: Re: Trashed case?
Post by Kropatchek on 10/22/07 at 03:19:48

Psycobilly wrote:

How available are cases, while I'm waiting?

Practicaly none.
Was one for sale in the UK last week on E-bay, went for 78 BrP. New price 560 USD and there's NO bearings nor bolts in it.

You can replace the starter gear ( the one with the missing teeth) and glue the broken-off pieces with JB-weld, has been done before. Search the forum.

After repair make sure the decompression solenoid is working correctly, as this is probably the cause of the failure.

Title: Re: Trashed case?
Post by Savage_Greg on 10/22/07 at 05:19:41

Until I see the photo, I'm not sure what part you are talking about. Here's a stator and cover for 49.95 on eBay.

http://cgi.ebay.com/ebaymotors/1995-Suzuki-LS6-LS650-650-Savage-Magneto-Stator_W0QQcmdZViewItemQQcategoryZ35595QQihZ008QQitemZ180168616051QQtcZphoto

And here is a complete bottom end for $199

http://cgi.ebay.com/ebaymotors/1995-Suzuki-LS6-LS650-650-Engine-Cases-Crankshaft_W0QQcmdZViewItemQQcategoryZ35595QQihZ008QQitemZ180171888279QQtcZphoto

Title: Re: Trashed case?
Post by Psycobilly on 10/22/07 at 18:20:00

http://w3.bikepics.com/pics/2007%5C10%5C22%5Cbikepics-1064116-full.jpg

Title: Re: Trashed case?
Post by Psycobilly on 10/22/07 at 18:42:52

Thanks for the links Savage Greg. I need to learn the search lingo for ebay. I tried to post a photo, but couldn't get it to put the pic in the post. Bummer.

I think I need to search the sight a little bit, but don't have the extra time, right now. I have seen a lot of usefull tech.

As for JB Weld, my grandad sweared by the stuff! ;D

Title: Re: Trashed case?
Post by Savage_Greg on 10/22/07 at 21:49:29

Psycobilly wrote:

http://w3.bikepics.com/pics/2007%5C10%5C22%5Cbikepics-1064116-full.jpg

There I messaged that one for you.

Now, what is damaged?

Title: Re: Trashed case?
Post by Psycobilly on 10/23/07 at 03:13:31

I will get digital pics today. I tried to draw a line to the busted holes, using the ebay link you sent. I suck at photo posting, but I can't even get a digital camera to work. ;D Maybe I'll wait until next week to tear into it. With my luck this week, I need to.

Title: Re: Trashed case?
Post by Kropatchek on 10/23/07 at 07:34:24

Savage_Greg wrote:

Until I see the photo, I'm not sure what part you are talking about.

There you go:
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ih=010&sspagename=STRK%3AMEWA%3AIT&viewitem=&item=200162868059&rd=1

Title: Re: Trashed case?
Post by slavy on 10/23/07 at 07:51:22

Like a rule, brocken crankcase means a new engine /there are some exeptions when You can weld and machine the area/, so Your best bet is to put some money together and start looking for one.
You said that the bike was sitting in the yard for a long time. What is the condition of the rest of the bike /inside the tank, electrical, are all the body parts there ?
What year is the bike? How many miles?
There is a fact that the electrical of the engine /rotor + stator/ must match with the wiring harness and the rest of the el. components . other words- 86-88 model is different from later models.
After looking at this factors, You will have to decide do you want to fix and keep this bike , or you will preffer to buy a new one and use this one for parts, or sell the parts off this abd buy a running one.

Title: Re: Trashed case?
Post by Psycobilly on 10/23/07 at 18:58:07

Okay, general consensus is, a new set of cases. I think that best, and I will start looking locally.

For the rest of the bike, a lot of rust externally. Tank has major pitting, and a hole about an eighth of an inch. Seat, is fubar, and no tranny cover, all fasteners, bolts, and nuts missing. Scary, maybe, but I'm used to bringing back a lot of older things. My 45 Harley for instance. Stator cover was removed and left off, with minor surface rust on the flywheel.

Electrical system, is also FUBAR. Cut wires everywhere, but no big problem. I saw a lot of diagrams last night searching this site. Miles unknown, but a fresh rebuild. or new engine would be in order. I'm sure with the experience here, I will find my way.

My camera is finally operational, so i will maybe, get savage Greg to post some photos tomorrow. He was really helpful in getting my halfa$$ diagram above linked in.

Anyways, this is nothing I'm scared of. I just hated the bike had no resting place. It needs a dry, warm place. The rest is just time. I can turn a wrench, and ask a lot of stupid questions. I was told as a boy, patience and persistence, pays off. We'll see!

Title: Re: Trashed case?
Post by Mr 650 on 10/30/07 at 13:29:03

Might consider parting that one out and finding one that runs.