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General Category >> Rubber Side Down! >> Starter gear/Engine block Repair
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Message started by Venturi on 10/19/19 at 14:15:19

Title: Starter gear/Engine block Repair
Post by Venturi on 10/19/19 at 14:15:19

Hello All! I have a question about a pre-‘96 starter gear problem. I read the threads on the torque limiter upgrade and understand what that entails. I have a 1987 motor that has the mounts for the starting gears busted(see photo). I don’t want to pay a welder and machinist to repair the block. Has anyone used JBweld or similar to add material back to the block and drilled it to accommodate the gears? I’ve only done this on aluminum before (a couple AR receivers I machined out after JBweld repairs). Would this even be strong enough?

Title: Re: Starter gear/Engine block Repair
Post by SpamyToo on 10/19/19 at 17:35:33

Those dont appear to be threaded, are they?

It looks like those are mating points to be used with collar inserts. Maybe Im wrong.

They are just for alignment I believe, so no torque on them or stress really. Looks like someone used them for a pivot point to pry with a screwdriver or something.

Title: Re: Starter gear/Engine block Repair
Post by SpamyToo on 10/19/19 at 17:40:20

Ahh, you must be referring to this.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1288911670/0

Its still not a threaded boss, just carries the shaft. But I imagine in use as starter gears it will see some stress.

Thats hard to say if jbweld will be enough. The stuff is crazy awesome and works for so much. So Id say, maybe.. But if it fails it could be real ugly.

Title: Re: Starter gear/Engine block Repair
Post by Venturi on 10/19/19 at 18:54:35

To be honest, I don’t even know if the damage I’m seeing on my motor is conducive with what would be seen from a lack of torque limiter. Can anyone confirm that this is the common problem from this year group engine? It seems like too much torque from “kickback” would put a metric nuts-ton of stress on those mount points. I’m just wondering if I JBweld and remove stock to get it as close to original as possible... would there still be too much pressure on it even if I upgrade the gears?

Title: Re: Starter gear/Engine block Repair
Post by verslagen1 on 10/19/19 at 20:04:40

I don't think JBweld would hold any better in a kick back event.

I would have a steel sleeve made to press over the boss once you got it back together.

and definitely covert to the torque limiter gear.

Title: Re: Starter gear/Engine block Repair
Post by Venturi on 10/19/19 at 20:54:22

Verslagen1, do you have a picture or drawing of what you said about pressing a steel sleeve over the boss? Is that in addition to JBweld or in lieu of?

Title: Re: Starter gear/Engine block Repair
Post by Dave on 10/20/19 at 06:06:30

Venturi:

Where are you located?

I have a good 4 speed bottom end you can have - I don't want to spend several hours packing and figuring out how to ship it to give it away.

If you can pick it up....you can have it.

Dave

Title: Re: Starter gear/Engine block Repair
Post by batman on 10/20/19 at 07:52:23

I'd take Dave up on his generous offer, rather than a repair that might fail over time, but I'd be concerned with what caused that damage in the first place. Converting to the anti kickback gear would prevent this , but there's other things that may have caused it , be sure that you use the proper rotor and MATCHING ignition TDI module (the magnets for the pickup coil are in different places on the 4 and 5 speeds ) , so the timing is correct, running the carb slightly rich will help prevent kickback ,as well as shifting the bike to neutral and pulling the choke out just before hitting the kill switch , this makes the fuel/air mix in the exhaust header so rich that there isn't enough oxygen to support combustion ,so that kickback cannot occur.

Title: Re: Starter gear/Engine block Repair
Post by Venturi on 10/20/19 at 09:22:08

Thanks Batman. This ‘87 motor is what came with the bike I got for $300. The starer motor gear mounts were busted as well as the teeth on the large gear (not sure the name of it; see photo). I’ve already rebuilt the bike with an ‘05 or ‘06 5-speed. I was hoping to get the ‘87 motor up and running also but it’s not critical.

Having said that; Dave, I would take the 4-speed bottom end you have if you’re within driving distance but would definitely give you cash for it.

Title: Re: Starter gear/Engine block Repair
Post by Fast 650 on 10/20/19 at 10:01:29

If you are looking at replacing the bottom end anyway, consider swapping in the later engine that already has the torque limiter installed. You only need to swap your rotor onto the newer engine and bolt it in.

Check the marketplace section, I think SoC still has a 5 speed listed there that has minor head damage from an accident, and your head is a bolt on for it.

Title: Re: Starter gear/Engine block Repair
Post by verslagen1 on 10/20/19 at 11:49:33

Well, here's another idea.

Drill the case deeper and put in a longer shaft.

If there's not much back there and you break thru, make it a press fit and leave it in there.