SuzukiSavage.com - Starting Problem

verslagen1

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Re: Starting Problem
Reply #15 - 10/09/13 at 22:50:11

TheProduct2007 wrote on 10/09/13 at 22:47:35:

Actually the gear next to it. I remeber there being two small gears one that looks like two (or three) gears connected to each other then one beside it that is near the actual starter gear. I believe they both had washers on them. I know the one near the starter gear does because it was the one that the washer fell off and I put back on.

wrong gear, both go on the front one. that's why the starter won't turn.
loosen the stator cover and suddenly the starter can turn.

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TheProduct2007 Junior Member Offline SuzukiSavage.com Rocks! Posts: 90	Re: Starting Problem Reply #16 - 10/09/13 at 22:51:31 This is also something i noticed just a minute ago. I took the bike off the stand and rolled it in neutral. Its a little harder to move now and I hear something clinking as I move it. I can't tell if its coming from the belt pulley near the engine or the starter case.
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TheProduct2007

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Re: Starting Problem
Reply #17 - 10/09/13 at 22:55:23

verslagen1 wrote on 10/09/13 at 22:50:11:

wrong gear, both go on the front one. that's why the starter won't turn.
loosen the stator cover and suddenly the starter can turn.

Do I need to apply remove the fresh gasket and put on another one?
I will do this during the weekend and upload some pictures just to make sure I'm on the same page with you because I don't want to screw up. BTW verslagen1 you've been a great help. I'm trying to get a better undertstanding as to what is going on with it.
Would the starter not turning free cause the lights to shut off though?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Starting Problem Reply #18 - 10/09/13 at 23:10:40 if you can get the cover off w/out tearing the gasket you can reuse it. some have repaired a small tear with rtv. you're stalling a big motor, it's going to dim your lights at least. if your battery is weak, it's going to do that.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Starting Problem Reply #19 - 10/10/13 at 09:28:09 That otta heat a wire up pretty good..
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TheProduct2007

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Re: Starting Problem
Reply #20 - 10/13/13 at 20:55:07

As ya'll mentioned earlier that I may have put the washer on the wrong gear. I could not find a picture of the alternator case opened but I did find a breakdown picture that shows the inside area of that case. In this pic I have drawn a line between the two gears because it looks as though in this picture they put the three sprocket gear to the right closer to the starter gear and the regular gear between that gear and the crankshaft gear. I circled in red the gear that I put a washer on (on the outside, closer to the crankcase) BUT that gear is not in the same place as the one is in the picture

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TheProduct2007 Junior Member Offline SuzukiSavage.com Rocks! Posts: 90	Re: Starting Problem Reply #21 - 10/14/13 at 13:43:31 Does anyone have a picture of the inside of the alternator cover?
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Steve H Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1223 Spartanburg, SC Gender:	Re: Starting Problem Reply #22 - 10/14/13 at 18:54:48 I do but they don't have the torque limiting gear in them. Just the regular ones.
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TheProduct2007 Junior Member Offline SuzukiSavage.com Rocks! Posts: 90	Re: Starting Problem Reply #23 - 10/15/13 at 20:07:31 Which one is the torque limiting gear? Would it go one to the right of the crankshaft gear or two?
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Steve H Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1223 Spartanburg, SC Gender:	Re: Starting Problem Reply #24 - 10/15/13 at 20:42:34 The torque limiting gear is the stack of 3 thin gears. It goes closest to the crankshaft and drives the big crankshaft gear with the little gear on the back side of it. If I have read other posts correctly, both washers go on this gear, one on the engine side and one on the cover side. Someone please correct me if I am wrong on this.
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TheProduct2007 Junior Member Offline SuzukiSavage.com Rocks! Posts: 90	Re: Starting Problem Reply #25 - 10/15/13 at 20:50:28 Ok Thanks Steve, that was what I was wondering is if the limiter gear went next to the crankshaft because it looks as though on the diagram it went next to the starter gear. I've got to drain the oil then I will take off the stator case and trying this again.
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