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General Category >> Rubber Side Down! >> Broke my starter torque limiting gear.
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Message started by och on 10/07/22 at 23:27:02

Title: Broke my starter torque limiting gear.
Post by och on 10/07/22 at 23:27:02

Ugh, super frustrating. For the last couple of month I've been trying to solve an oil leak from my stator cover. My mechanic tried three times and failed. I took the bike back home and now I'm doing it myself, taking a slow and very thorough approach. I took the bike apart today and removed the stator cover, cleaned it, sealed the stator plug with permatex ultra black, and set it aside for 24hr for the sealant to cure.

In the meantime, when I removed the cover, the two gears came out - I believe one is called torque limiter gear and the other is called idler gear. When I tried to put them back in, I couldn't get the idler gear to go all the way in, and I noticed that it is being caused by one of the sprockets on the torque limiting gear being out of alignment with the other two. I tried to spin the sprockets by hand and with a screwdriver, no luck. So I decided to undo the retaining snap ring, and now I can spin and align the sprockets, but there is no way I can assemble the gear assembly. I think it requires some kind of factory press to snap that retaining ring back in place.

Anyone else ever run into this issue?

This is a picture of said gears from another thread.

http://suzukisavage.com/yabb2.2/Attachments/830F6A18-CF43-4202-AEFD-6539FAAA1C92.jpg

Title: Re: Broke my starter torque limiting gear.
Post by Dave on 10/08/22 at 02:45:52

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1386968592

Title: Re: Broke my starter torque limiting gear.
Post by och on 10/08/22 at 05:28:07

Dave, thank you so much.