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General Category >> Rubber Side Down! >> Help me get my new project bike running!!
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Message started by joshbur237 on 08/28/21 at 18:52:26

Title: Help me get my new project bike running!!
Post by joshbur237 on 08/28/21 at 18:52:26

Hey all,
I have recently purchased a 1997 suzuki savage as a project bike, was completely taken apart when I bought it and I have replaced the engine with a used one I bought from a motorcycle repair shop. Having some issues with getting it running, the engine was supposed to have ran with no issues when taken out of the last bike but I cannot get spark, I have replaced the cdi and starter relay. How do I test if the stator is bad without the bike running?

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 08/28/21 at 18:54:29

I have also tested the ignition coil with an ohm meter and it read as good and the battery is brand new and charged, all my grounds are good and the starter will turn but no spark. The decompression system is off the bike which I was told should not effect it but the decomp control is still there as the starter will not turn over when I take it off.

Title: Re: Help me get my new project bike running!!
Post by verslagen1 on 08/28/21 at 20:21:02

33362A313B2C2B6B6A6E590 wrote:

How do I test if the stator is bad without the bike running?

The bike will run w/out the stator as long as the battery is charged... so that's not your problem.

Title: Re: Help me get my new project bike running!!
Post by verslagen1 on 08/28/21 at 20:23:39

74716D767C6B6C2C2D291E0 wrote:

So you push the start button and what happens?
We gotta go thru this step by step to find out what's wrong.

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 08/28/21 at 20:38:36

3C2F3839262B2D2F247B4A0 wrote:

[quote author=74716D767C6B6C2C2D291E0 link=1630201946/0#1 date=1630202069]I have also tested the ignition coil with an ohm meter and it read as good and the battery is brand new and charged, all my grounds are good and the starter will turn but no spark. The decompression system is off the bike which I was told should not effect it but the decomp control is still there as the starter will not turn over when I take it off.

So you push the start button and what happens?
We gotta go thru this step by step to find out what's wrong.[/quote]

The clutch and neutral switches were previously bypassed but I fixed that, In neutral with the clutch in I hit the start button and you can hear the starter solenoid clicking and the starter whirring, engine not turning over no thump. With the spark plug out and grounded to the engine there is no spark.

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 08/28/21 at 20:45:53

The cdi was from a 2001 bought it off ebay from a reputable seller, he said it was taken off a running bike with only 2000 miles. New starter solenoid off Amazon as it had the wrong one wired on when I got the bike. The engine was taken apart when I got the bike and I bought a replacement one out of a 1998 from a motorcycle repair shop was said to run no issues. I believe all my grounds to be good. I also cleaned most all electrical connections with contact cleaner and replaced both the 20 amp fuses and the spark plug properly gapped

Title: Re: Help me get my new project bike running!!
Post by verslagen1 on 08/28/21 at 21:35:41

282D312A203730707175420 wrote:

The clutch and neutral switches were previously bypassed but I fixed that, In neutral with the clutch in I hit the start button and you can hear the starter solenoid clicking and the starter whirring, engine not turning over no thump. With the spark plug out and grounded to the engine there is no spark.

Ok, starter whirring, engine not turning... did you mean that?
That would mean that the starter clutch is in backwards.

If the engine is turning but not firing, check you have power the TCI (ig box) and the coil.

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 08/29/21 at 09:56:45

33203736292422202B74450 wrote:

Yes starter solenoid clicks, starter whirs. Nothing else engine doesnt turn over. So how do I turn the starter clutch back around. Very disappointed to hear it could be something wrong in the motor itself since I was told it had no issues at all from the shop I got it. Would that prevent the bike from making spark? Still have no spark.

Title: Re: Help me get my new project bike running!!
Post by verslagen1 on 08/29/21 at 11:18:32

53564A515B4C4B0B0A0E390 wrote:

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 09/02/21 at 16:13:03

283B2C2D323F393B306F5E0 wrote:

[quote author=53564A515B4C4B0B0A0E390 link=1630201946/0#7 date=1630256205]
Yes starter solenoid clicks, starter whirs. Nothing else engine doesnt turn over. So how do I turn the starter clutch back around. Very disappointed to hear it could be something wrong in the motor itself since I was told it had no issues at all from the shop I got it. Would that prevent the bike from making spark? Still have no spark.

I involves pulling the rotor and you'll need a special tool to do that.
SO let's take 1 more step to confirm this is the problem.
Remove the starter and bench test it. Note the direction the spindle rotates.
Remove the sparkplug (make sure it clean up there, you don't want any dirt falling into the cylinder).
If you put your fingers in where the starter came out, you'll feel the gear that the starter engaged with.
Put it in a high gear and push the bike forward to rotate the engine. You might want a friend to do this for you.
While you push it forward, the gear should not turn.
Now pull it backwards, the gear should turn.

If it does turn while going forward, the starter clutch is in backwards.[/quote]
So I found alot of metal shaving upon changing the oil filter, so I decided to pull the bottom end covers off before doing anything else. Found quite a bit of damage under the clutch cover,have yet to pull the other side off. Looks like I've been sold a bad engine I drove almost 8 hours round trip to get the thing too >:( Still gotta take the other side cover off to see the damage there. What's this damage looking like??

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 09/02/21 at 16:14:24

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Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 09/02/21 at 16:15:06

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Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 09/02/21 at 16:16:00

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Title: Re: Help me get my new project bike running!!
Post by verslagen1 on 09/02/21 at 16:52:08

The clutch throwout lever on the inside of the cover has a nasty habit of breaking in 2 when HD springs are put in. One of those pieces probably got caught up in the basket.

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 09/02/21 at 17:07:42

4B584F4E515C5A58530C3D0 wrote:

The clutch throwout lever on the inside of the cover has a nasty habit of breaking in 2 when HD springs are put in. One of those pieces probably got caught up in the basket.

Yeah I'm thinking this is my issue... is my whole flywheel gone???Even with the spare bottom end I have...is this engine done?

Title: Re: Help me get my new project bike running!!
Post by verslagen1 on 09/02/21 at 18:06:08

You have a broken out boss for the pinion gear and the starter clutch ring gear is missing teeth.

A new bottom end will be easier.

This is definitely not a running engine with no problems.

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 09/02/21 at 21:58:58

455641405F5254565D02330 wrote:

You have a broken out boss for the pinion gear and the starter clutch ring gear is missing teeth.

A new bottom end will be easier.

This is definitely not a running engine with no problems.

There was a bottom end on the bike when I got it and top end taken apart in a box. I figured a used engine would be the quickest route to get on the road and I've never done engine work that's why I went with that. I really didnt think a semi reputable repair shop would scam me like that. lll have to check out the engine that came with it to see if I can get it back together. What a bummer :(

Title: Re: Help me get my new project bike running!!
Post by verslagen1 on 09/02/21 at 22:25:34

So that bike was an '88 or so and the engine is a '97.
You need to swap the rotors or it won't run right.

just swap the good parts from the '88 to the '97.

Title: Re: Help me get my new project bike running!!
Post by joshbur237 on 09/02/21 at 22:30:54

:-[ :-X
6A796E6F707D7B79722D1C0 wrote:

So that bike was an '88 or so and the engine is a '97.
You need to swap the rotors or it won't run right.

just swap the good parts from the '88 to the '97.

The bike is a 97 and the used engine is supposed to be a 98, deff a 5 speed so should be no issue to make a good engine out of the 2. Thanks for the help brotha will keep you updated

Title: Re: Help me get my new project bike running!!
Post by DragBikeMike on 09/02/21 at 22:48:25

I'm having a hard time wrapping my head around just how those broken teeth from the starter ring gear got all the way over to the right side of the engine and up into the clutch. Is it possible that something else jammed up the clutch? That could have overloaded the starter drive and caused the ring gear failure.

As Verslagen mentioned, the clutch release cam is known to fail. What does your clutch release cam look like? Can you post a picture?

How about the starter torque limiter. Does it have one? The limiter should have prevented damage to that ring gear. Can you post a picture of the torque limiter?

Thanks for all the other pics. Great info.