SuzukiSavage.com - Starter Gear Upgrade

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28754 L.A. California Gender:	Re: Starter Gear Upgrade Reply #15 - 09/27/11 at 07:25:39 I'd measure the difference in the gears for myself. remember there's supposed to be washers on either side of that gear. And I do think it's the same idle gear for any year.
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SurfJunkie Junior Member Offline SuzukiSavage.com Rocks! Posts: 66	Re: Starter Gear Upgrade Reply #16 - 10/06/11 at 11:24:52 Ive got all the schematics needed to make the electronic fix. Ill source the parts and see how much they cost. I work for a consumer electronics company as a Engineer/Tech, and solder daily. After i have the components, it shouldn't take me very long to make this.
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BurnPgh

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Re: Starter Gear Upgrade
Reply #17 - 11/14/11 at 20:30:55

someone on the german savage forum was making them if i recall and they worked, but after a few years a few started to fail and the one exhast valve that the decompressor acts on was held open. Not great. probably cheaper to go electrical and more robust to swap gears and, if necessary, case covers. Both are possible. Both work. One has failed. The other, so far, has not.

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matos YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Starter Gear Upgrade Reply #18 - 11/15/11 at 15:19:58 going the electrical solution, whats the worst thing it can happen when it fails?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28754 L.A. California Gender:	Re: Starter Gear Upgrade Reply #19 - 11/16/11 at 12:06:04 The chief problem with the exh valve being held open is no power and loss of rpm's. I don't think it'll ruin it, just your day and maybe a pair of shoes.
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matos YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Starter Gear Upgrade Reply #20 - 11/16/11 at 14:24:08 Thank you verslagen1, that was the answer i was looking for, im gona try the electrical fix and later on ill look for a good deal on the gears.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28754 L.A. California Gender:	Re: Starter Gear Upgrade Reply #21 - 05/24/12 at 21:56:36 Couldn't get at the '88, so I measured the '02. straight edge over the side of the case (where the gasket goes) it measure 12mm exactly to the boss of the pinion gear. and the idle gear boss is exactly even.
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Bobber Fett

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Re: Starter Gear Upgrade
Reply #22 - 05/31/12 at 05:15:42

Quote:

Couldn't get at the '88, so I measured the '02.
straight edge over the side of the case (where the gasket goes)
it measure 12mm exactly to the boss of the pinion gear.
and the idle gear boss is exactly even.

How far below the lower edge of the starter driven gear is the boss of the pinion/idle gear?

On the original gear the teeth that interact with the starter driven gear (#8) are flush with the pinion boss, but on the new gear there is a washer added plus a new lip created because the center shaft protrudes from the gear a bit (~0.049" if I remember). I'll need to get the boss of the pinion gear lowered until those additional distances are gone (or close to it). Then the teeth on the new gear and the starter driven gear will be in the same plane.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28754 L.A. California Gender:	Re: Starter Gear Upgrade Reply #23 - 08/17/12 at 11:37:10 87 savage wrote on 08/17/12 at 11:06:58: Incidentally I got a limiter assembly on ebay that came off a 1998 VL1500 which uses the same part. thanks 87, I didn't know that.
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giannishazel

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Re: Starter Gear Upgrade
Reply #24 - 02/26/13 at 13:28:35

OK.so i have a pre 95 model(650)and i am going to do the upgrade.i bought the case cover(of later 95) and the torque limiter gear.
1.can i just put the new torque gear next to my idle gear and then the new case cover?
2.would i need anything else?
3.as i can see the torque gear has 2 washers one on each side.does the idle gear have a washer?
4.are the gaskets the same of pre 95 and later 95 of the cover ?
5.and a last question.is there an oil passage at the screws of the cover case and if there is at which screw?
thanks a lot..and pre 95 owners do this upgrade cause i found this trouble the hard way..the case had about 5cm cracks on idle gear position and a piece was missing on the place the other gear sat...thanks god for the good welders

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28754 L.A. California Gender:	Re: Starter Gear Upgrade Reply #25 - 02/26/13 at 13:49:29 1. yes, the post95 cover is wider, but the same at the idler. 2. no. 3. you need washers on the torque limiter gear only, as both sides of the shaft are splined. The idler gear does not because it's smooth. 4. yes. 5. no.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28754 L.A. California Gender:	Re: Starter Gear Upgrade Reply #26 - 12/29/14 at 21:14:22 Also note the location of the washer... It goes on the shaft shown and not on the shaft with the X.
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ryanwilliam YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 15	Re: Starter Gear Upgrade Reply #27 - 01/15/15 at 14:57:21 I've got an 87 and I am working on sourcing the idler gear and a newer stator cover. (If anyone has either, PM me.) Will I have to remove the stator to switch the gears? If so, what type of puller tool will I need?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28754 L.A. California Gender:	Re: Starter Gear Upgrade Reply #28 - 01/15/15 at 15:04:11 ryanwilliam wrote on 01/15/15 at 14:57:21: Will I have to remove the stator to switch the gears? If so, what type of puller tool will I need? Rarely, sometimes you need to align a relief in the stator to the position and sometimes it'll go in anywhere.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28754 L.A. California Gender:	Re: Starter Gear Upgrade Reply #29 - 04/13/20 at 21:00:29 On stator covers without the torque limiter, the boss is .513" below the surface. On stator covers with the torque limiter, the boss is 1.034" below the surface.
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