SuzukiSavage.com - starter teeth broken

Dogpoo Ex Member	starter teeth broken 01/21/06 at 11:03:12 I just found out that a few starter teeth are broken. Should I take apart the LH cover to remove the broken teeth? Also, when taking apart starter, a screw got sucked into the black hole. HOw do I recover that screw? I got a quote for a new starter. Something like 400 canadian. Anyone have one for cheaper. It's an 86 savage. Cheers
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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: starter teeth broken Reply #1 - 01/21/06 at 11:15:19 Better take the cover off !! They have a problen with breaking the case where the starter gear idler gear mounts inside the case !!! Once the cover is off, slide the 2 gears off and inspect the case.. Mine has been welded up and seems to work fine...
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vroom1776 Serious Thumper Offline Posts: 2110 Gender:	Re: starter teeth broken Reply #2 - 01/21/06 at 12:06:45 Junk yard or ebay for that starter motor... yeah, gotta get those teeth outa there! Black hole: try a magnet on a stick. http://cgi.ebay.com/ebaymotors/86-SUZUKI-SAVAGE-LS650-LS-650-CHROME-STARTER_W...
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Digger Serious Thumper 2005 No Login Offline Ya gotta be tough to ride singles! Posts: 1604 Colorado Springs, CO Gender:	Re: starter teeth broken Reply #3 - 01/22/06 at 08:57:54 Black hole tip: On my bike (see signature) the starter is very easy to get off. I pulled it off and cleared several things out of the well, including an unidentified item. I hate when that happens! Now, whenever I'm doing any work in that area of the bike, I cover the starter motor area w/ a rag.
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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: starter teeth broken Reply #4 - 01/26/06 at 10:48:37 Dog ?? Tell us what you found was the prob with your bike?? Was it starter only or other things also ??
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Dogpoo

Ex Member

Re: starter teeth broken
Reply #5 - 01/26/06 at 13:43:27

We'll this is what I have found. The gears that turn the flywheel, from the starter to the flywheel, those mounts are broken. There is a couple of teeth missing from the flywheel, a missing tooth from a gear that turns the flywheel, and broken starter gears inside of the cover. Looks like I will have to get a new flywheel, weld the gear mounts, and new gears, plus an armiture for the starter. I'll let you know how it goes.

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: starter teeth broken Reply #6 - 01/26/06 at 13:46:49 Just out of curiosity, what year is the bike? I was wondering if this might be a result of the reported backlash issue.
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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: starter teeth broken Reply #7 - 01/26/06 at 15:53:18 Mine has been welded up also !! Its an 87 Now Dog, bet your glad you pulled the side cover instead of just putting in a new starter !! 2 damaged starters Now that would hurt even worse !!
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: starter teeth broken Reply #8 - 01/26/06 at 22:46:06 I used this in another post to show timing marks, but what parts? You have teeth off the rotor too?
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Kropatchek

Serious Thumper

Offline

Why more than 1
cylinder?

Posts: 1457
Alphen a/d Rijn Netherlands
Gender: male

Re: starter teeth broken
Reply #9 - 01/27/06 at 01:25:05

Savage_Rob wrote on 12/31/69 at 16:00:01:

Just out of curiosity, what year is the bike? I was wondering if this might be a result of the reported backlash issue.

The backlash issue, that's right!

The starter gears and their bearing supports are weak designed. Have been beefed up in 1991. Furthermore the design was revised again in 1996 with the incorporation of a limiter in the second gear.

To avoid future damage on pre-1991 Savages you can install an electronic devise that opens the exhaust valve when the engine is switched off.

Will post the scematic later to-day.

Greetz
Kropatchek Grin

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Never ask your bike to scream before her throat is warm.
'93 Sav in '96 ( yellow) looks

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: starter teeth broken Reply #10 - 01/27/06 at 05:51:07 Stop The Backlash Thread Antiklack Plans If you run the URL from the above link through Altavista's Babelfish translator, you can read it pretty well.
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Kropatchek

Serious Thumper

Offline

Why more than 1
cylinder?

Posts: 1457
Alphen a/d Rijn Netherlands
Gender: male

Re: starter teeth broken
Reply #11 - 01/27/06 at 07:02:40

Savage_Rob wrote on 12/31/69 at 16:00:01:

Stop The Backlash Thread

Antiklack Plans
If you run the URL from the above link through Altavista's Babelfish translator, you can read it pretty well.

This design works without relais. And with the kind permission of Gerd Honnacker of the German LS650 forum I post it here.

Gerd made one for me, I did the installation and it works fine. No more "fart"when switching of the engine. The device is hardwired and put into a "plastic"tube of about 1/2 by 1" which can be placed anywhere you like.

Greetz
Kropatchek Grin

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Never ask your bike to scream before her throat is warm.
'93 Sav in '96 ( yellow) looks

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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: starter teeth broken Reply #12 - 01/27/06 at 08:38:42 Greg... On your pic.. Remove the two smaller gears. Where they ride in the case, It breaks the case out and has to be welded and redrilled to accept the shaft the gear rides on... Mine looks like crap from the previous owner but seems to be holding up.....
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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: starter teeth broken Reply #13 - 01/28/06 at 18:06:24 Dogpoo ... any way for you to take a pic of your case with the 2 small gears removed for show and tell ??
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Dogpoo Ex Member	Re: starter teeth broken Reply #14 - 01/28/06 at 18:06:54 Pretty much, teeth of every gear from the starter to the Flywheel are missing teeth. Does anyone know how to get the flywheel off. Do I jut unscrew the bolt inside of the LH cover, that is attached to the Flywheel and magnetic part? I am scared of unscrewing it, don't know what will happen?
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