AGGGH just had a nice long post compiled and lost it when I went to submit it because it had a link in it (and was my first post).

Here is the brief recap:
1988 Savage needed starting clutch replaced (missing teeth).  Ordered new style idler gears and side case at same time.  When put back together, starter does nothing when starter button pressed.  Works if untorque case bolts.  Found a couple different references on this site to some washer binding the starter if work has been done in left side of engine.  However, haven't been able to find specifics.

Parts diagram for 1996 shows 2 thrust washers (one on each side of Limiter Assembly, ST).  Are both needed?  Or only one?  Or neither?  None were in there originally (and the 1988 diagram shows none).  Those are the only washers I can see that might make a difference.  Am I looking in the wrong place?

I like working on my bike, but would rather be riding it......

Any help would be appreciated.

Although I had no issues with my '88, there's been a report that the pinion gear didn't mesh fully with the starter clutch gear.  And that maybe the case was modified for better fit.  And there has been a number of complaints that the starter gear teeth break.  So this maybe true that early models had an engagement problem and was resolved with a case change.  Since yours had the starter clutch teeth breakage, it may be the issue.

A washer is required on both sides of the torque limiter because there are no smooth surfaces there.  If it's binding, you may have to find some thin washers.

Generally, when the cover is removed, one of the washers will leap off and it is invarirably put back in the wrong spot and will cause the binding.  both washers go on the torque limiter.

And I'm assuming you're using a late model cover as well?

"Generally, when the cover is removed, one of the washers will leap off and it is invarirably put back in the wrong spot and will cause the binding."
The parts diagram doesn't show any washers on the original idler gear #1, and I don't believe there were any in there.

both washers go on the torque limiter.
Good to know, then I have it installed correctly.

And I'm assuming you're using a late model cover as well?Yes, I am.

could I just be over-torquing the case?  I didn't tighten them that tight.....

deanwheeler wrote on 05/21/12 at 12:07:13:

No, you'd have to squeeze out the gasket if you were.

If you can, put a straight edge across the case over where the pinion gear sits and measure the distance between the boss and the straight edge.  I'll try and find time to do the measurement on the '88.

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.

In addition, I measured the thickness of the thrust washers from Suzuki at .8mm apiece.

As Oldfeller suggested, I left the back washer on (toward engine) and that makes both idler gears line up (all 3 teeth across the torque gear grab metal on the idler gear).  I left the front (outermost) washer off and bolted the cover on.  No gaskets, no form-a-gasket, no spacers of any kind, nothing but case to case.  In this condition, the engine will roll over.

The Suzuki gasket wasn't thick by any means, so I won't gain much clearance there.  And unfortunately, much of the form-a-gasket squeezes out due to the magnetic pull of the stator when I slide the case on, so I won't gain much there.  Since the engine rolls in the current configuration, does anyone know the drawbacks of leaving just one washer on?  I wasn't sure if Oldfeller suggested this as a test only, or as a permanent solution.

It seems like it would work, but what works in my mind doesn't always work in the real world