Derek
Ex Member
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Hey trickbikedude, not to worry. Allow me to make a contribution to this forum. I have heard of a couple other Savages with the same problem. Your repair is very do-able. I bought my '86 this year with the same problem. I can walk you through the repair, and without taking the engine off the bike. First, get the manual and you'll need new/used parts to replace those broken ones: idler gears, pins, starter clutch assembly, gasket, etc. There is enough thickness in the left side crankcase wall to drill out a smaller diameter hole about 1/4" deeper than original to sit the new idler gear pin into and simply turn the new/old pin on a lathe to make the end 1/4" the same diameter as the drill bit you use. It will be stronger than original and will save your engine. Make sure you cover over the lower oil passages with rags or the drilled materials will end up in your crankcase...not a good thing. If you need more details of my repair job, let me know. It does not take long and the job is holding fine.
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