Home
Forum
Search
Login
Register
Merch
Donate
Welcome, Guest. Please
Login
or
Register
::
View Members
SuzukiSavage.com
›
General Category
›
Rubber Side Down!
› Starter gear/Engine block Repair
(Moderators:
verslagen1
,
Dave
,
Serowbot
)
‹
Previous topic
|
Next topic
›
Pages: 1
Starter gear/Engine block Repair (Read 105 times)
Venturi
YaBB Newbies
Offline
SuzukiSavage.com
Rocks!
Posts: 34
Starter gear/Engine block Repair
10/19/19 at 14:15:19
Hello All! I have a question about a pre-‘96 starter gear problem. I read the threads on the torque limiter upgrade and understand what that entails. I have a 1987 motor that has the mounts for the starting gears busted(see photo). I don’t want to pay a welder and machinist to repair the block. Has anyone used JBweld or similar to add material back to the block and drilled it to accommodate the gears? I’ve only done this on aluminum before (a couple AR receivers I machined out after JBweld repairs). Would this even be strong enough?
Back to top
01685149-28AC-4D5C-981E-1E9984A32A15.jpeg
IP Logged
SpamyToo
Full Member
Offline
Posts: 233
Re: Starter gear/Engine block Repair
Reply #1 -
10/19/19 at 17:35:33
Those dont appear to be threaded, are they?
It looks like those are mating points to be used with collar inserts. Maybe Im wrong.
They are just for alignment I believe, so no torque on them or stress really. Looks like someone used them for a pivot point to pry with a screwdriver or something.
Back to top
IP Logged
SpamyToo
Full Member
Offline
Posts: 233
Re: Starter gear/Engine block Repair
Reply #2 -
10/19/19 at 17:40:20
Ahh, you must be referring to this.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1288911670/0
Its still not a threaded boss, just carries the shaft. But I imagine in use as starter gears it will see some stress.
Thats hard to say if jbweld will be enough. The stuff is crazy awesome and works for so much. So Id say, maybe.. But if it fails it could be real ugly.
Back to top
IP Logged
Venturi
YaBB Newbies
Offline
SuzukiSavage.com
Rocks!
Posts: 34
Re: Starter gear/Engine block Repair
Reply #3 -
10/19/19 at 18:54:35
To be honest, I don’t even know if the damage I’m seeing on my motor is conducive with what would be seen from a lack of torque limiter. Can anyone confirm that this is the common problem from this year group engine? It seems like too much torque from “kickback” would put a metric nuts-ton of stress on those mount points. I’m just wondering if I JBweld and remove stock to get it as close to original as possible... would there still be too much pressure on it even if I upgrade the gears?
Back to top
IP Logged
verslagen1
YaBB Moderator
ModSquad
Offline
Where there's a
will, I want to be
in it.
Posts: 28890
L.A. California
Gender:
Re: Starter gear/Engine block Repair
Reply #4 -
10/19/19 at 20:04:40
I don't think JBweld would hold any better in a kick back event.
I would have a steel sleeve made to press over the boss once you got it back together.
and definitely covert to the torque limiter gear.
Back to top
Versey's Place
Tech Section Index
IP Logged
Venturi
YaBB Newbies
Offline
SuzukiSavage.com
Rocks!
Posts: 34
Re: Starter gear/Engine block Repair
Reply #5 -
10/19/19 at 20:54:22
Verslagen1, do you have a picture or drawing of what you said about pressing a steel sleeve over the boss? Is that in addition to JBweld or in lieu of?
Back to top
IP Logged
Dave
YaBB Moderator
ModSquad
Offline
SuzukiSavage.com
Rocks!
Posts: 18110
Camp Springs, Kentucky
Gender:
Re: Starter gear/Engine block Repair
Reply #6 -
10/20/19 at 06:06:30
Venturi:
Where are you located?
I have a good 4 speed bottom end you can have - I don't want to spend several hours packing and figuring out how to ship it to give it away.
If you can pick it up....you can have it.
Dave
Back to top
Someday I will be old......But not today!
IP Logged
batman
Serious Thumper
Offline
SuzukiSavage.com
Rocks!
Posts: 3806
osceola new york
Gender:
Re: Starter gear/Engine block Repair
Reply #7 -
10/20/19 at 07:52:23
I'd take Dave up on his generous offer, rather than a repair that might fail over time, but I'd be concerned with what caused that damage in the first place. Converting to the anti kickback gear would prevent this , but there's other things that may have caused it , be sure that you use the proper rotor and MATCHING ignition TDI module (the magnets for the pickup coil are in different places on the 4 and 5 speeds ) , so the timing is correct, running the carb slightly rich will help prevent kickback ,as well as shifting the bike to neutral and pulling the choke out just before hitting the kill switch , this makes the fuel/air mix in the exhaust header so rich that there isn't enough oxygen to support combustion ,so that kickback cannot occur.
Back to top
my old work mates called me MacGyver
IP Logged
Venturi
YaBB Newbies
Offline
SuzukiSavage.com
Rocks!
Posts: 34
Re: Starter gear/Engine block Repair
Reply #8 -
10/20/19 at 09:22:08
Thanks Batman. This ‘87 motor is what came with the bike I got for $300. The starer motor gear mounts were busted as well as the teeth on the large gear (not sure the name of it; see photo). I’ve already rebuilt the bike with an ‘05 or ‘06 5-speed. I was hoping to get the ‘87 motor up and running also but it’s not critical.
Having said that; Dave, I would take the 4-speed bottom end you have if you’re within driving distance but would definitely give you cash for it.
Back to top
CA791D81-0FDA-40B2-9888-B4BD4466E584.jpeg
IP Logged
Fast 650
Senior Member
Offline
SuzukiSavage.com
Rocks!
Posts: 405
Valrico, FL
Gender:
Re: Starter gear/Engine block Repair
Reply #9 -
10/20/19 at 10:01:29
If you are looking at replacing the bottom end anyway, consider swapping in the later engine that already has the torque limiter installed. You only need to swap your rotor onto the newer engine and bolt it in.
Check the marketplace section, I think SoC still has a 5 speed listed there that has minor head damage from an accident, and your head is a bolt on for it.
Back to top
IP Logged
verslagen1
YaBB Moderator
ModSquad
Offline
Where there's a
will, I want to be
in it.
Posts: 28890
L.A. California
Gender:
Re: Starter gear/Engine block Repair
Reply #10 -
10/20/19 at 11:49:33
Well, here's another idea.
Drill the case deeper and put in a longer shaft.
If there's not much back there and you break thru, make it a press fit and leave it in there.
Back to top
Versey's Place
Tech Section Index
IP Logged
Pages: 1
‹
Previous topic
|
Next topic
›
Forum Jump »
» 10 most recent posts
» 10 most recent topics
General Category
»» Rubber Side Down!
- Technical Documents/Reference
- The Marketplace
- The Cafe
- Politics, Religion (Tall Table)
- Forum Upgrade Issues / Tests
« Home
« Home
SuzukiSavage.com
10/04/24 at 16:16:20
›
General Category
›
Rubber Side Down!
› Starter gear/Engine block Repair
SuzukiSavage.com
» Powered by
YaBB 2.2
!
YaBB
© 2000-2007. All Rights Reserved.