SuzukiSavage.com - Cylinder cover/head & cylinder overhauling

slickiverson YaBB Newbies Offline Posts: 31 Norway Gender:	Re: Cylinder cover/head & cylinder overhauling Reply #30 - 01/22/14 at 07:04:03 I just received an email from my local Suzuki dealer. $486 for the "Clutch set starter". It doesn't seem it is possible to buy just the cogwheel. Does anybody have a used one in good condition to sell me? The bike is a Suzuki Savage LS650 from 1987. Thanks for the help guys! This forum is awesome!
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Dave

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Re: Cylinder cover/head & cylinder overhauling
Reply #31 - 01/22/14 at 07:06:20

You don't need to remove the flywheel to work on the starter clutch. The flywheel nut requires a 46mm deep socket - as the crankshaft sticks out too far to allow a normal socket to be used......but it doesn't matter to you for the replacement of the starter clutch gear.

Why did the bike lose a tooth? Does your bike have the starter torque limiter? Has the case or left side cover been broken as well when the tooth was broken?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Cylinder cover/head & cylinder overhauling Reply #32 - 01/22/14 at 07:21:18 errr... yes you do. we are talking about the big gear behind the flywheel right? not the little torque limiter? The flywheel fits on a taper with a key. A 46mm socket is worthless by itself. Only there to aide you when you use the flywheel puller.
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slickiverson

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Re: Cylinder cover/head & cylinder overhauling
Reply #33 - 01/22/14 at 07:22:31

Hello Dave! So how do I replace the starter gear then?

Dave wrote on 01/22/14 at 07:06:20:

You don't need to remove the flywheel to work on the starter clutch. The flywheel nut requires a 46mm deep socket - as the crankshaft sticks out too far to allow a normal socket to be used......but it doesn't matter to you for the replacement of the starter clutch gear.

Why did the bike lose a tooth? Does your bike have the starter torque limiter? Has the case or left side cover been broken as well when the tooth was broken?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Cylinder cover/head & cylinder overhauling Reply #34 - 01/22/14 at 07:27:21 and BTW, this is a known problem. The late model bikes have a torque limiter gear that replaced the pinion gear. Here's a link to the fix... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1288911670
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Dave

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Re: Cylinder cover/head & cylinder overhauling
Reply #35 - 01/22/14 at 07:48:10

I still believe you don't need to remove the flywheel - but you do need to remove the rotor, and you will need the rotor puller to do that.

In the following diagram you can see that you do not need to remove the nut listed at #7....or the flywheel. Not sure the size of #7 nut...maybe the 46mm nut you are referring to is the one that holds the rotor in place....and not the flywheel.

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starter20clutch20old.jpg

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Cylinder cover/head & cylinder overhauling Reply #36 - 01/22/14 at 08:43:42 Ah... ok... it's early yet. The big spinny thing on the end is a 'rotor'... ya gotta pull that off. The big spinny thing behind everything else is a 'flywheel'... no need to do anything with that. another cuppajo if you please
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