Hmmm. This is not my area of expertise, but did you thouroughly check out the new unit prior to install? A search of the forum revealed the following that might be worth referencing for your situation.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1210886378/8#8Re: Electrickery!
Reply #8 - 05/24/08 at 17:14:44 Sorted this one out - the starter motor was shorting out - the innards were in poor condition when I took it appart, loads of debris fell out of the case and the smell of burnt shellac was not pleasant at all. The short was robbing the ignition system of the power to produce a spark.
Then there is this, which relates to verslagen1's post.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1211481002/4#4 Re: HELP I have hit Technical Hitch with starter
Reply #4 - 05/23/08 at 00:49:10 I fear the difference between the old style and new style starter mechanisms completely prevents any compatibility. The addition of the clutch mechanism in the new style was in answer to the problem of the old starter and gears tendency to backlash and break the starter motor from the crankcase.
Sad to report that I know of no work-around to make the parts you have work together; and it sounds like you are now in the market for a late model left side engine cover. Probably best off to use the newer "clutch" system anyways and save your crankcase from possible future damage. Brand new left side crankcase cover is about $75 from Ron Ayer's.
New (second hand) starter installed and the beasty finally woke up!
It's also been stated here that the starter motor is the single biggest drain of the battery, next to the headlight. Is your battery in good shape? Hope this provides you with at least soem possible leads. Best of luck!
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