SuzukiSavage.com - wont start, different issue

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28889 L.A. California Gender:	Re: wont start, different issue Reply #30 - 12/07/10 at 14:33:52 That's 22mm out. Typically, it wobbles up and down til it taps on the case. sometimes it goes side to side.
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greenmonster

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Re: wont start, different issue
Reply #31 - 12/07/10 at 17:55:52

Max, I wasn't able to get the plug on the left hand crankcase cover off. Seems to be set in there pretty tightly. I'll see if I can make some kind of tool to take it off while I'm in the shop tomorrow. Otherwise, it's starting to look like I'm draining the oil and pulling to cover off, again.

I hate working on my bike outside in the winter. I have about 10 minutes when I get home before it's too dark to see anything I may have dropped.

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mick

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Re: wont start, different issue
Reply #32 - 12/07/10 at 19:08:41

greenmonster wrote on 12/07/10 at 17:55:52:

Max, I wasn't able to get the plug on the left hand crankcase cover off. Seems to be set in there pretty tightly. I'll see if I can make some kind of tool to take it off while I'm in the shop tomorrow. Otherwise, it's starting to look like I'm draining the oil and pulling to cover off, again.

I hate working on my bike outside in the winter. I have about 10 minutes when I get home before it's too dark to see anything I may have dropped.

bring the bike into the kitchen,or the living room. That's what I would do,I used to put christmas lights on mine.

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justin_o_guy2

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Re: wont start, different issue
Reply #33 - 12/07/10 at 21:13:16

There are some inexpensive worklights at the Big Box stores. I got a short tripod with 2 500 watt lamps on it for about 20 bux, The downside is the lamps dont last & cost about 6 bux apiece. But, knowing what I know about them, Id buy it again if I just really needed some light. Plenty of lighting options out there, extension cords arent hard to land,,Temporary shelter, not a problem,, a tarp to work on, instead of just dirt, 5 dollars will get a tarp, a layer of cardboard, just because theres no building doesnt mean the only option is the raw outdoors.

If I could find a tent for real cheap, big enough,,, well,,

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greenmonster

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Re: wont start, different issue
Reply #34 - 12/07/10 at 21:54:05

grand ideas, all of them. However, I like being married so the bike doesn't get to come inside. Wink

And sadly, I live in a townhouse, the bike shares a single parking spot under the sundeck with my car. I usually do any work on it at the shop I work in. Plenty of room, all the tools I need, or at least the machines to make the tools I need.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: wont start, different issue Reply #35 - 12/07/10 at 23:13:01 Where do you live?
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greenmonster Senior Member Offline Hellooooo Nurse! Posts: 420 Vancouver BC Gender:	Re: wont start, different issue Reply #36 - 12/07/10 at 23:17:15 Vancouver, BC
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: wont start, different issue Reply #37 - 12/08/10 at 07:15:49 Ohh, well, working outside with no wind block should be no big deal then,, CRIPES!! Id Have to have some kinda wall to get behind. I hate the cold, I hate the cold IT HURTS my body.. You can have my share.
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Max_Morley

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Re: wont start, different issue
Reply #38 - 12/08/10 at 17:11:06

The edge of a used (or new) front brake pad does a pretty good job of fitting the slot in the crank bolt cover. Others have used a couple of washers to get the correct thickness to fill the slot and an adjustable end wrench. They may have to be ground some to fit correctly. Good cycle shops will have a 3 armed special tool that is supposed to work, mine needed to be harder as it bent. If you are around aviation folks, they have cowl fasteners (duetz? or something like that) that use a tool that I've ended up using. Think I found it at a garage sale one weekend. Also the tool trucks will have a 3/8 drive tool for adjusting old style (20'-50's) tie rod ends that can be made to fit. A new o ring and a light hand on reassembly will make the next time easier. Sure don't envy you working outside, in the cold and dark as it is much easier to miss the small part that falls down and messes up the job. My tug had both side covers off while still connected to the side car and they both leaked, had the rubber sealing washers on the wrong bolts and a gasket folded over and pinched. I separated them and did the jobs over and no more leaks in 2 years now. I use a Handy bench and provide some cushioning and lay it over so the side I'm working on is facing mostly up so I can properly clean and inspect the sealing surface and it keeps the remaining oil from dripping out. Max

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Max at Thumper Acres. '96 Savage bagger, '03 Savage w/Cozy sidecar for wifeni.

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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: wont start, different issue Reply #39 - 12/11/10 at 21:30:41 Green, Did you ever try letting the starter crank the engine with the spark plug pulled out? If so, what happened? Good luck!
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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: wont start, different issue Reply #40 - 12/11/10 at 21:34:25 Max_Morley wrote on 12/08/10 at 17:11:06: .....A new o ring and a light hand on reassembly will make the next time easier..... As will a little Never-Seize on the plug's threads.
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greenmonster

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Re: wont start, different issue
Reply #41 - 12/13/10 at 10:20:26

I pulled the tank this weekend, pulled the plug and the starter still wouldn't move anything. (there goes the compression theory. too bad, it was a good one.)
I tried rotating the tire with the plug out to see if the engine was moving at all. I was only able to move the wheel in 3rd and 4th gear. At which point I wasn't able to tell if the motor was turning over the sound of my panting.

Still couldn't get the side plug out, I did however begin shaving off chunks of metal and bend the 3/4" washer that I was using. Figuring that I'm going to have to take the side cover off again and see if there is something messed up on the starter clutch I drained the oil again and that's when I ran out of daylight. Stupid sun.

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Bubba

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Re: wont start, different issue
Reply #42 - 12/13/10 at 12:29:07

Green, I'd be very interested in what you find. It sounds like the same thing I'm running into except that now I've pulled the engine and I'm working on some stripped bolts on the head cover.

I did notice that when looking at the ronayers.com fiche it looks like the washers go on the limiter and mine has only one washer on the starter gear.
I think someone put it back together wrong and the gears are binding against the side cover...I think versy suggested that may be happening...

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'06 lt Blue, Dyna Power pipe, air screw 2 1/4 turns, 52.5 pilot w/ bleed holes, 150 Main, 2/3 spacer, Pirelli MT66 tires, Raptor petcock, 412-4006 Progressive shocks

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greenmonster Senior Member Offline Hellooooo Nurse! Posts: 420 Vancouver BC Gender:	Re: wont start, different issue Reply #43 - 12/13/10 at 12:41:51 unfortunately the 86 doesn't have the torque limiter that has those washers. I think that may have come in around the time that they started putting in the elusive 5th gear. which I think, i could be wrong, was in 95 or 96.
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Bubba Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 956 Denver, CO Gender:	Re: wont start, different issue Reply #44 - 12/13/10 at 12:44:25 Yes, mine is a '97. I'd still be interested in what you find...because it sure sounds like what I'm running into...
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