SuzukiSavage.com - Magneto (Left) Cover Not Seating

Jeremy

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Magneto (Left) Cover Not Seating
06/18/17 at 07:42:09

I'm slowly putting my '95 Savage back together. I had the left side case cover off to paint it, but I can't seem to get it seated now that I'm putting it back on. Everything towards the front seems good, but towards the back along the top, there is about an 1/8th inch gap that I just can't seem to get closed. If you look dead on at the left side cover, the spot that won't seat is at about 2 o'clock.

If I take off the gear that the starter motor engages, it seems to fit snugly, so I'm guessing that has something to do with it.

Been looking at The Motorcycle Handyman pictures and I think I have everything lined up correctly. The post seats in the engine block, the spring goes over the post, then the gear goes on next, then the side cover. The gears are all meshing, so that isn't the problem.

Is there some sort of trick that I'm missing?

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Jeremy Junior Member Offline SuzukiSavage.com Rocks! Posts: 54 Philadelphia Gender:	Re: Magneto (Left) Cover Not Seating Reply #1 - 06/18/17 at 07:47:50
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Jeremy

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Re: Magneto (Left) Cover Not Seating
Reply #2 - 06/18/17 at 08:04:34

I probably should have paid more attention when I took this cover off last year Grin

I do notice that if I don't put the spring I have behind the gear that meshes with the starter gear, everything seems good.

I had the spring in my little baggie and it fits perfectly on the post, and since I can't see it in any pictures, it seems like it must belong behind the gear and is just hidden from view.

It's a pretty thin spring and tough to see, but can anyone verify if the spring belongs where I have it in this pic?

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verslagen1

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Re: Magneto (Left) Cover Not Seating
Reply #3 - 06/18/17 at 08:20:39

Jeremy wrote on 06/18/17 at 08:04:34:

I probably should have paid more attention when I took this cover off last year Grin

I do notice that if I don't put the spring I have behind the gear that meshes with the starter gear, everything seems good.

I had the spring in my little baggie and it fits perfectly on the post, and since I can't see it in any pictures, it seems like it must belong behind the gear and is just hidden from view.

It's a pretty thin spring and tough to see, but can anyone verify if the spring belongs where I have it in this pic?

https://photos.smugmug.com/Other/Savage/i-Pg3sfKq/0/bfc93154/L/IMG_1464-XL%20...

There's not supposed to be a spring there. Just take it out.

If ever you are confused on what parts go where, look at a OEM parts diagram
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1290238904/0#0

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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Magneto (Left) Cover Not Seating Reply #4 - 06/18/17 at 08:26:23 I agree with Versy , doesn't belong there , remove it , should be a thin shim/washer behind that gear.
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Magneto (Left) Cover Not Seating Reply #5 - 06/18/17 at 08:28:55 Get a manual , also parts pictures can be helpful on arrangement !
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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: Magneto (Left) Cover Not Seating Reply #6 - 06/18/17 at 08:48:31 Ruttly wrote on 06/18/17 at 08:26:23: I agree with Versy , doesn't belong there , remove it , should be a thin shim/washer behind that gear. No washers on the gears, only the torque limiter! And he doesn't have one.
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Magneto (Left) Cover Not Seating Reply #7 - 06/18/17 at 10:33:23 Odd mine has I guess you would call them a thrust washer behind the gear.
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Magneto (Left) Cover Not Seating Reply #8 - 06/18/17 at 10:55:25 I stand corrected the parts breakdown show just what you said. I will have that cover off in a week or two to check cam chain & swap out the clutch rod so I will check that too. Thanks Versy
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verslagen1

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Re: Magneto (Left) Cover Not Seating
Reply #9 - 06/18/17 at 10:56:01

Ruttly wrote on 06/18/17 at 10:33:23:

Odd mine has I guess you would call them a thrust washer behind the gear.

Straight gears shouldn't need them.
If yours run fine with them... ok, but don't feel like you have to run out and get them if you don't have them.
The torque limiter has them and many times someone will replace them on the idle gear and cause the starter to bind up.

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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Magneto (Left) Cover Not Seating Reply #10 - 06/18/17 at 11:00:54 So 1996 is the first year of the torque limiter ?
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Jeremy Junior Member Offline SuzukiSavage.com Rocks! Posts: 54 Philadelphia Gender:	Re: Magneto (Left) Cover Not Seating Reply #11 - 06/18/17 at 11:02:43 Thanks!!! I guess I have to go searching my workbench for those missing parts. I tried looking on the parts blowups at bike bandit, but couldn't find what I was looking for.
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Jeremy Junior Member Offline SuzukiSavage.com Rocks! Posts: 54 Philadelphia Gender:	Re: Magneto (Left) Cover Not Seating Reply #12 - 06/18/17 at 11:03:38 Ruttly wrote on 06/18/17 at 11:00:54: So 1996 is the first year of the torque limiter ? If so, that'll make my life a lot easier. I may not have to search for the missing part!
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Magneto (Left) Cover Not Seating Reply #13 - 06/18/17 at 11:03:54 Use suzukipartsmonster.com
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verslagen1

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Re: Magneto (Left) Cover Not Seating
Reply #14 - 06/18/17 at 11:15:16

Jeremy wrote on 06/18/17 at 11:03:38:

Ruttly wrote on 06/18/17 at 11:00:54:

So 1996 is the first year of the torque limiter ?

If so, that'll make my life a lot easier. I may not have to search for the missing part!

If that's your pic of the stator side, then you don't have a torque limiter.
and yes, I think '96 is the 1st year.

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