SuzukiSavage.com - Starting Problem

TheProduct2007

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Starting Problem
10/09/13 at 18:55:24

1996 Suzuki Savage with 12,000 miles.
I recently had to replace the head gasket so I had to remove the engine from the frame. It took a week to fix to reassemble because I lost the circle clip that connected to the cam chain tensior. I reassembled the engine and put it back on the frame. Connected the wires running from the handle bar switches and the gas tank back up. I tried starting it and once I would hit the engine start button it would make one click and then all the lights (including spedometer light and neterual light) would go off until I released the engine start button. I figured it was a dead battery so I put the battery back on the charger and let it charge. I put it back in after a full charge and it did the same thing. What could be the issue?

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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 #1 - 10/09/13 at 19:09:05 did you take the stator cover off? have you adjusted the decomp solenoid? what voltage does the battery charge to?
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TheProduct2007

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Re: Starting Problem
Reply #2 - 10/09/13 at 19:16:06

I did take the stator cover off. I don't believe I adjusted the solenoid the decomp solenoid. And I'm not sure what the battery charges to. I don't have a circuit tester, the battery charger I use states it upon percentage level of a complete charge. The battery has started with only 50% battery life but that was on a old battery a long time ago. I make sure it's 100%

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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 #3 - 10/09/13 at 19:42:56 TheProduct2007 wrote on 10/09/13 at 19:16:06: I did take the stator cover off. ding! we have a winner! There's a washer that falls out when you take the cover off. you're not likely to put it back in the right spot w/out asking. the washers go on the pair of gears, not the single gear.
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TheProduct2007

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Re: Starting Problem
Reply #4 - 10/09/13 at 19:56:34

I know which washer you are talking about. I made sure I connected it before I put the stator back on, it fell off as soon as I took the stator cover off so I made sure i put it back on when I had to put the stator back on. Would that washer really cause one click and make all the lights turn off until I release the engine start button?
I did notice a couple of things that might help.
-The horn and lights will work fine as well as brake switches.
-After continued attempts at starting, there was one time where I hit the eninge start button and the lights did not come back on after I released the button. I also noticed a tiny amount of smoke coming from near the airbox/battery compartment. I instantly removed the battery and quit trying and decided to get on here.

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WD Serious Thumper 2005 No Login Offline Professional "scooter trash". Posts: 5207 Rosemark TN Gender:	Re: Starting Problem Reply #5 - 10/09/13 at 20:10:33 What washer? No washer fell out of mine... It did take a week to find the single cog's roller though... If I have to open the thing back up for a friggin' washer... oh, yeah, have to open it back up anyway, it leaked out a full sump overnight...
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TheProduct2007

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Re: Starting Problem
Reply #6 - 10/09/13 at 20:17:04

WD wrote on 10/09/13 at 20:10:33:

What washer? No washer fell out of mine... It did take a week to find the single cog's roller though... If I have to open the thing back up for a friggin' washer... oh, yeah, have to open it back up anyway, it leaked out a full sump overnight... Shocked

I found a washer in mine, its also in the diagram for the stator cover. I think its to prevent the gear from sliding upward and rubbing against the stator cover.

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TheProduct2007 Junior Member Offline SuzukiSavage.com Rocks! Posts: 90	Re: Starting Problem Reply #7 - 10/09/13 at 20:18:38 Just to double check because I'm feeling kind of stupid right now since I've spent a lot of energy working on the bike today. When you mean "stator cover" are you talking about the generator cover? Where the high powered magnet is located?
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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 #8 - 10/09/13 at 20:23:05 yup, stator... generator... all the same depending on who you talking to. the cover where electrons come from. the single gear doesn't have enough room for a washer. and if you bolt the cover down with one in there it'll stall the starter.
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WD Serious Thumper 2005 No Login Offline Professional "scooter trash". Posts: 5207 Rosemark TN Gender:	Re: Starting Problem Reply #9 - 10/09/13 at 20:43:05 I'll double check when I pull the cover off and reseal it. Knew I should have brought the Panhead instead of the Suzukis and the Honda. Not like I had much choice, the friend I got it from, wanted it back... easy come, easy go.
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TheProduct2007

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Re: Starting Problem
Reply #10 - 10/09/13 at 21:50:27

So you are saying the washer needs to be removed? If the starter is stalling then it is stalling instantly with the push of the button, that single click sound does sound like it is coming from the starter or at least near it. But what would that explain the small smoke coming from near the battery compartment? What should I do to fix this issue?

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TheProduct2007

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Re: Starting Problem
Reply #11 - 10/09/13 at 22:03:40

Ok I've gotten a bit confused. verslagen1 I'm not sure what you mean the washer goes on both gears and then state there is no room for a washer.
I went a rechecked my sources for disassembly and reassembly for the generator cover and it through me off.
BikeBandit.com (where I order some of my hard to find parts) shows there is a washer between the gear (next to the starter gear) and the stator case but the manual doesn't show one.

If it is something as simple as this washer, why would my lights shut off when pushing the engine start button?
If I have to take off the stator case will I have to get a new gasket (since I already put a new one on, or can I use RTV on the case?

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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 #12 - 10/09/13 at 22:42:16 see starter gear #1? the one that looks like two gears stuck to each other? washers go on either side on all '95 and later.
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TheProduct2007

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Re: Starting Problem
Reply #13 - 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.

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TheProduct2007 Junior Member Offline SuzukiSavage.com Rocks! Posts: 90	Re: Starting Problem Reply #14 - 10/09/13 at 22:49:32 verslagen1 wrote on 10/09/13 at 22:42:16: washers go on either side on all '95 and later. Either side or one on each side?
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