SuzukiSavage.com - Stator side cover removal.

humblegeo Junior Member Offline SuzukiSavage.com Rocks! Posts: 74	Stator side cover removal. 06/18/14 at 13:56:02 Does the oil need to be drained before removing stator side cover or is it dry on that side?
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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: Stator side cover removal. Reply #1 - 06/18/14 at 14:24:03 Wet But you could tip the bike over about 45° and it'd be dry.
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humblegeo

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Re: Stator side cover removal.
Reply #2 - 06/18/14 at 15:32:48

That worked for a quick cover removal. No mess But also no washers on starter gear. Gear turns in one direction when cover is removed, won't turn either direction when cover is installed. The previous owner must have been in there for some reason and the thrust washers got lost since it all kind of falls apart when you remove the cover. He must have been looking at the stator. If I can ever get this bike running I may find that there is a charging issue next. Sad

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Stator side cover removal. Reply #3 - 06/18/14 at 18:56:25 The gear that is closest to the starter does not have any washers, the next gear has a washer on each side. If you get he washers in the wrong place, the gear is too tight and won't turn when you tighten up the cover.
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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: Stator side cover removal. Reply #4 - 06/18/14 at 20:45:29 I'd get a magnet and go fishing just in case one got lost in the sump. who knows, you might find a watch.
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dhabicht1 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 23	Re: Stator side cover removal. Reply #5 - 06/19/14 at 06:26:25 just had the same problem and thanks to some good advice I have it sorted. I posted a pic if you want a closeup of the gears.
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28660 Tucson Az Gender:	Re: Stator side cover removal. Reply #6 - 06/19/14 at 09:18:18 I have a special "gift" for goofing up up that washer... ...
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humblegeo Junior Member Offline SuzukiSavage.com Rocks! Posts: 74	Re: Stator side cover removal. Reply #7 - 06/21/14 at 17:01:00 my trust washer is missing in action. can I pick up something over at Lowes that will do the job?I assume it's a steel washer and probably very thin?
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S-P Serious Thumper Offline Back in the saddle again Posts: 816 Phoenix, AZ Gender:	Re: Stator side cover removal. Reply #8 - 06/21/14 at 18:45:41 Lowe's has a decent metric specialty shelf. Ace Hardware has become my go to for metric nuts, bolts and special fasteners.
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humblegeo

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Re: Stator side cover removal.
Reply #9 - 06/30/14 at 19:57:10

Tried a washer today but when I started to tighten up side cover things got tight and the gear wouldn't turn. Washer was too thick I'm sure. Clearance must be critical on that. Strange that the gear will turn freely with the side cover off but wont turn with the side cover on and no washer. Ill try a thinner washer tomorrow if that is still too tight then Ill go ahead and order a $2.00 washer from bikebandit I guess.

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oldNslow

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Re: Stator side cover removal.
Reply #10 - 07/01/14 at 08:32:00

humblegeo wrote on 06/30/14 at 19:57:10:

Tried a washer today but when I started to tighten up side cover things got tight and the gear wouldn't turn. Washer was too thick I'm sure. Clearance must be critical on that. Strange that the gear will turn freely with the side cover off but wont turn with the side cover on and no washer. Ill try a thinner washer tomorrow if that is still too tight then Ill go ahead and order a $2.00 washer from bikebandit I guess.

Any chance that BOTH washers are on the same(back)side of the gear? Or that the washer there is the wrong one - too thick?

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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: Stator side cover removal. Reply #11 - 07/01/14 at 08:44:36 They are 2 thin washers... I'd guess about .010" thick.
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humblegeo

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Re: Stator side cover removal.
Reply #12 - 07/01/14 at 09:32:24

Tried a thinner washer and now the starter spins the motor over like a champ. Thanks for all the help with a rather difficult issue that was about to eat my lunch!!! Who would ever have thought that a small missing washer would lock the starter up and prevent it from rotating the motor (engine). These forums are so great since so many of the members have years of experience working specifically on the Suzuki Savage.

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