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General Category >> Rubber Side Down! >> Problem with Starter clutch (I think)
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Message started by VOLKY on 12/23/11 at 11:45:47

Title: Problem with Starter clutch (I think)
Post by VOLKY on 12/23/11 at 11:45:47

Ok. I removed the left side engine cover to polished it. Reinstalled the engine cover and I have this problem.

After I tighten the bolts for the engine cover and try to start the engine, you can hear a click from the starter selenoid, but it won't turn the engine. I thought it was a low, bad, or dead battery so i bought a new battery and had the same results. I removed the engine cover again and reinstalled, but this time I didn't tighted the bolts. Then starter works, engages and turns the engine. As soon as I tighted the engine cover again, I have the same problem, you can hear the started clicking but it will not turn the engine. I again loosened the bolts of the engine cover and the engine turns.

What am i doing wrong? Seems like when I tightened the bolts, something (starter gear or starter clutch) get jammed some how?

Any suggestions or solutions?

Title: Re: Problem with Starter clutch (I think)
Post by Boule’tard on 12/23/11 at 11:55:27

I think there is a washer or two that have to back juuuust right, or else you'll get that problem.

Sorry I'm no help. Verslagen with the correct answer in 3..2..1..

I think this is it:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1303397342

Title: Re: Problem with Starter clutch (I think)
Post by verslagen1 on 12/23/11 at 12:09:19

Yep, you got the washers in wrong.

There's an idler gear, no washers on this one.

And a spur gear, a big one and a little one together. Washer goes on either side.

that should fix you up.

Title: Re: Problem with Starter clutch (I think)
Post by VOLKY on 12/24/11 at 15:36:06

You guys were right. I had one washer in the wrong place. Amazing what one little washer can do or not do. Now it turns with no problems. Thanks.
Well, i got a new battery after this mess. It needed one anyways. :P

I will post pictures of the stuff i have done to the bike soon.