I just received a savage fro free that needs some work. I was able to get it started, but was making a wierd clunking noise, then eventually is stalled with that clunking noise. I then proceeded to do oil change, drain gas and refill, etc. Now it will not start (starter makes a clicking noise, but it is because the engine will not turn). I tried turning the engine by hand using a 17mm socket and I took out the spark plug. It was turning, but with effort, I beleive it should turn nice and easy. I try to push start it, but the bike has some resistance pushing it with the clutch engange and in first gear, then when I release the clutch, the tire skids and the engine cannot be turned over. Any ideas what this can be? I'm thinking it might be the clutch.

Thanks in advance

Rob

Sounds like it's siezed somewhere!

Just thinking about my early 2 stroke days!
It could be that it has run dry of oil at some point, especially with the clunking sound. You should be able to turn it by hand without much resistance with the plug removed, although don't quote me on that cos I haven't tried on this bike, and I am not a mechanic!
Why was it free and what did the owner tell you?

How much oil came out of the engine when you changed it and was there any signs of metal in it?

At least try to get the enigine to turn, on a nice size hill pull clutch in, place bike in 2nd gear get some speed going, lean way back on the seat to put some weight on the rear tire, let clutch out fast, see if the engine turns.  if it doesn't your pretty much going to have to rebuild the engine.

Sounds turminal to me .... Maybe you should let me put it out to pasture........       Mine is an 87      Wait a min... I would get in more trouble,  I then would be blamed for having 2 Mistress's.......    

The motor I just took out of mine had the same problem (only reason I took it out was for oil leaks).

I had a welder weld aluminum across where the piece broke out and then CAREFULLY filed/grinded the hole round again.

Edit.... Make sure to not fill in the hole completly as you will need part of it to guage from when your filing the hole round again. Very important to not get it crooked or too large.

klinc, Did the take just the crankcase off of the bike and all of the other parts connected to the crankcase off? I've been told it's going to get too hot when they weld. Another one told me to use JB Weld, but I think it will just break off in a couple of weeks. Also, does anyone know if this gear is turning when the engine is started?

Now the big question is, do I put all my time into this and try to fix and hope that it works or should I give up, sell for parts and pick up a used one for around $2000. To do the repair I'm figuring $50 for all of the gaskets I took off, $10 for JB and then my time for putting it all back together.

Rob

Your engine is reparable, without welding, inexpensively. I received my '86 with the same problem. I simply drilled a bigger hole, being careful not to drill through to the crankcase wall and I put in the starter idler gear on a new pin with a larger diameter (step) to match the hole I drilled into the engine block wall. Cover the inside bottom section so drilled aluminum does not fall into the crankcase and take the time to pull off the flywheel as the damage debris jams behind the flywheel causing it to appear seized.  I thoroughly tested my work and the engine runs well.