SuzukiSavage.com - wont start. Electrical?

yetimeister YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 41 Maine Gender:	Re: wont start. Electrical? Reply #15 - 05/21/15 at 17:23:54 The wire is a single wore with a connector with a white strip. My harness is stock and whole.
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yetimeister

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Re: wont start. Electrical?
Reply #16 - 05/21/15 at 19:50:47

So I checked the valve clearances and they are all in spec. I have the valve/rocker cover off now and inspected the cam. It seems to be off timing. I have it at tdc and the two slash marks are not lined up with the top surface of the head. So I loosened the bolts toke the c clip off and am trying to get the sprocket and chain lined up with the cam. Everytime I get them lined up and almost all the way onto the cam it seems as though my chain wont give me quit enough slack to get it centered on the cam. Am I missing something here? I don't need to take the side cover off and mess with the tensioner do !? Thanks guys.

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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: wont start. Electrical? Reply #17 - 05/21/15 at 20:04:37 yetimeister wrote on 05/21/15 at 19:50:47: Am I missing something here? I don't need to take the side cover off and mess with the tensioner do !? Thanks guys. yes, you do.
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yetimeister

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Re: wont start. Electrical?
Reply #18 - 05/22/15 at 05:19:53

So last night shortly after I wrote that I got the cam sprocket and chain all lined up without having to get into the side cover. Bolted everything back up and went to bed. Woke up this morning went out and it fired right up! My timing was off. This is the good news. The bad news is now I seem to have a whining type noise coming from the bottom end area? Any ideas? Can't seem to catch a break here.

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Re: wont start. Electrical?
Reply #19 - 05/22/15 at 05:54:37

If the fellow that installed your cam can't get the timing right....no clue as to what else may be wrong.

If you didn't take off the clutch cover and release the cam tensioner...it could be your cam chain is too tight. When you had the cam sprocket loose the tensioner might have moved when the chain was slack....and when the tensioner takes a new "bite" on the ratchet it never lets go.

I believe you need to take the cover off and release the ratchet so it can remove some pressure on the cam chain. Then while you are in there look around and make sure it all looks correct.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: wont start. Electrical? Reply #20 - 05/22/15 at 05:57:05 That's where id start. No telling how hard it's pushing on the guides. I don't know how you managed it. You must have some strong hands.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18098 Camp Springs, Kentucky Gender:	Re: wont start. Electrical? Reply #21 - 05/22/15 at 05:57:52 Then when you have time go over and "dope slap" the guy that worked on your engine!
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Re: wont start. Electrical?
Reply #22 - 05/22/15 at 06:07:52

Thanks guys that's what my next step was but wanted to make get a second opinion. I'll pull the cover off when I get home and release it and see if that helps. Yeah let's just say once I get it all resolved I'll be giving him a call to inform him. I knew I should have just done it myself. As for strong hands I can't take full credit after a while I got it to line up just right and it didn't take much effort but was a hassle.

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Re: wont start. Electrical?
Reply #23 - 05/22/15 at 06:24:11

Left side inspection cover out, rotate CCW on bolt till marks line up on TDC,compression.
Unless you check and make sure that didn't change while wrangling with the chain,tensioner,etc, just bolting it up and calling it good can be a bad idea.
Considering the quality of the job, id sure wanna know that cover isn't in overly tight. They have been known to cause headaches if cranked down too tight.

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yetimeister YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 41 Maine Gender:	Re: wont start. Electrical? Reply #24 - 05/22/15 at 06:56:12 Thanks man. You mean the valve cover? I torque everything to soec so it shouldn't be an issue of torque tightness.
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Re: wont start. Electrical?
Reply #25 - 05/22/15 at 16:42:10

So I just pulled the clutch case cover. Nice little surprise I found. The tensioner is over extended and the only thing holding it together is the spring. Best way to tackle this without it grenading? Appears to not be chewed up. Explains my whinning noise.. Should I try and reuse it? Buy a new one? Buy a modified one? Can't really measure the length as its pooched at the moment. Bike only has 5500 miles and is a 98. Trying to figure out my next step haha. What a hassle this has turned into.

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yetimeister YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 41 Maine Gender:	Re: wont start. Electrical? Reply #26 - 05/22/15 at 16:43:23 Assuming this was due to the shop not getting my timing right? Never has this issue before.
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Re: wont start. Electrical?
Reply #27 - 05/22/15 at 17:02:09

yetimeister wrote on 05/22/15 at 16:42:10:

So I just pulled the clutch case cover. Nice little surprise I found. The tensioner is over extended and the only thing holding it together is the spring. Best way to tackle this without it grenading? Appears to not be chewed up. Explains my whinning noise.. Should I try and reuse it? Buy a new one? Buy a modified one? Can't really measure the length as its pooched at the moment. Bike only has 5500 miles and is a 98. Trying to figure out my next step haha. What a hassle this has turned into.

I don't know what you mean by "pooched" but if the adjuster doesn't appear to be damaged, I think the first thing I'd try is pulling it out, putting the spring and plunger back in the body, and re- installing it. Then see how far the plunger is extended. It might just have come apart while you were messing with the chain. At 5500 miles I don't think the chain should be stretched to the point where the adjuster would come apart.

A photo would be helpful.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: wont start. Electrical? Reply #28 - 05/22/15 at 17:17:20 I wasn't paying attention. The spring doesn't hold it together. Stiff piece of paper, corner on tensioner body, mark where protruding tube starts to taper to the attachment point. Then measure that. Low miles, should be good. A picture would be nice.
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yetimeister YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 41 Maine Gender:	Re: wont start. Electrical? Reply #29 - 05/22/15 at 17:46:11 Got it apart and put back together. Small scare on the side but not where the action takes place. Internals all look good still. Measures 8.4 mm. Pooched- = broken or in sometimes he's pooched!- tired /drunk lol.
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