This is a continuation of this thread:
http://suzukisavage.com/cgi-bin/YaBB.pl?board=RubberSideDown;action=display;n...I was changing the oil in my bike (see signature) and decided it was a good time to change the weeping o-ring where the starter motor plugs into the engine case.
With Suzuki Factory Part # 09280-35005 in hand, I pulled the starter and cleaned everything up. You can see from the photo that I found the weepage to be minimal. I really didn't need to do anything, but I already had everything apart with a new o-ring at hand.
I pried the old o-ring off. It appeared to be slathered in some sort of gasket cement or RTV. It also appeared to be (horrors!)
considerably thicker than the replacement o-ring I had waiting.
Out came the gauges.
New o-ring was 0.083" thick (the factory says it is 2.1mm thick).
The old o-ring was 0.120" thick (or just shy of 1/8").
The I.D of the engine housing where the starter motor goes was 1.576".
The O.D. of the o-ring seat on the starter motor was 1.381" (or just over 1 3/8").
After looking at these measurements, it was evident that the replacement o-ring would not work.
Fire up the computer and get on the web. Turns out the factory fiches list two different starter motors for my bike, but this o-ring supposedly stays the same for each of the two starter motors. I notice that the P/N on my starter motor does not match either of the two starter motors I'm finding online.
Back to the garage. I opened up my drawer of o-rings and found one that was close. 1 1/4" I.D. with a thickness of 0.140". I pop it on. The starter motor would not go into the engine case.
Off I go to, in order, Lowe's, Checker Auto, NAPA, AutoZone, and Advance Auto. At Lowe's, in the plumbing section, I see an o-ring with an I.D of 1 3/8" and a thickness of 1/8". Should be the ticket. The plumbing guy had no idea if it was an oil-resistant o-ring. I get scared-off and leave. No joy at Checker, NAPA, or AutoZone. At Advance, I buy an o-ring with an I.D. of 1 1/4" and a thickness of 1/8" (it was the best they could do). I get it home and measure the thickness. 0.140" !! This will not help me, as I've already tried an o-ring of that thickness with no luck.
Desperate now, I riffle through my o-ring drawer again. I find one with an I.D. of 1 1/4" and a thickness of 0.135". I slather on the silicone grease and......it fit. Tightly (which is good), but it fit.
So, any ideas what was up with the Suzuki Factory replacement o-ring?
BTW, I will post up again if this replacement o-ring starts leaking.
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