SuzukiSavage.com - Starter clutch gears DEAD

Moarpower

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Starter clutch gears DEAD
08/01/22 at 07:38:41

Hi guys. I'm in Australia New to these bikes and looks like the backlash got me..

I have an 1987. Just got all the wiring and Bobber kit installed and put about 200 miles on it since getting it back on the road a few weeks ago.

It has been running well. The last time I took it out before today it was a bit slugging on the first crank even though the battery was fresh. There was a bit of backfiring when letting off the throttle and it does backfire when I shut it off.

Today I went to start it and the starter area sounded horrible. Like a can of bolts shaking.

Opened up the case and we'll, the starter clutch gear is missing teeth along with the other cogs. No teeth missing on the starter itself but it does look worn.

I have no idea what to do now or how to prevent this in the future if I can even find the parts to repair.

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Starter clutch gears DEAD Reply #1 - 08/01/22 at 07:45:53 Not looking good at all. Heartbroken
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Starter clutch gears DEAD Reply #2 - 08/01/22 at 07:46:53 Quite a few missing in different places.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28890 L.A. California Gender:	Re: Starter clutch gears DEAD Reply #3 - 08/01/22 at 07:55:57 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1288911670
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Starter clutch gears DEAD Reply #4 - 08/01/22 at 08:08:43 Thanks Vers. Finding the 2 starter gears and the clutch gear is going to be a pain I think. I'll have to find the part number for the correct upgrade parts. Man this sucks.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Starter clutch gears DEAD Reply #5 - 08/01/22 at 08:37:24 12600-24B01 cheap on eBay. Hopefully thats compatible.
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Moarpower

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Re: Starter clutch gears DEAD
Reply #6 - 08/01/22 at 17:20:53

verslagen1 wrote on 08/01/22 at 07:55:57:

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1288911670

Sorry Vers. Are you able to help me identify the part numbers for the upgrade that I need ? Having a bit of trouble being certain before.i pull the trigger on buying and shipping parts as some say USA model and others say Japan depending on where I look.

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verslagen1

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Re: Starter clutch gears DEAD
Reply #7 - 08/01/22 at 18:41:59

Moarpower wrote on 08/01/22 at 08:37:24:

12600-24B01 cheap on eBay. Hopefully thats compatible.

that's the torque limiter gear
you'll also need the starter clutch 12600-24831

they're used in several engines so you can search generically if you want more options.

you can use your original cover, but it needs to be modified.

BTW, the last 2 digits of the p/n refer to the part revision level, any 2 digits should work.

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Starter clutch gears DEAD Reply #8 - 08/01/22 at 18:49:10 Thanks a ton. Will the starter clutch be a straight swap? Do you recommend many other preventative measures ? I really appreciate it mate.
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verslagen1

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Re: Starter clutch gears DEAD
Reply #9 - 08/01/22 at 20:07:06

Moarpower wrote on 08/01/22 at 18:49:10:

Thanks a ton.

Will the starter clutch be a straight swap? Do you recommend many other preventative measures ? I really appreciate it mate.

should be a straight swap, you can probably even mix parts.

just check the rubber plug the wires go thru for oil leaks.
you'll need a rotor puller and don't hit or drop the rotor.
mine lost charge and I don't remember if that happened or not but those are probable causes.

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Starter clutch gears DEAD Reply #10 - 08/01/22 at 20:49:42 Thanks again. Well hopefully I'm back on the road in a few weeks
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TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: Starter clutch gears DEAD Reply #11 - 08/01/22 at 21:15:41 With the torque limiter gear you will need to machine the side cover. The hole and boss for the shaft need to be approx. .115" deeper (needs to be precisely measured). Measure the difference between the thickness of the old versus new. The new needs two small washers, one on both sides of it for install.
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TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: Starter clutch gears DEAD Reply #12 - 08/01/22 at 21:18:49 Another option is to buy a later model side cover, but used you are gambling with condition. I opted for the machine shop route instead.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Starter clutch gears DEAD Reply #13 - 08/01/22 at 23:53:24 Thanks Sneeze
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Starter clutch gears DEAD Reply #14 - 08/03/22 at 18:04:49 Would it help avoid that if a fellow was to wire a switch so as to push a button and fire the decomp to kill the compression and flip the kill at the same time?
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