SuzukiSavage.com - Well, I reached the end of the line with my S40

och

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Re: Well, I reached the end of the line with my S4
Reply #15 - 10/15/22 at 15:10:24

justin_o_guy2 wrote on 10/15/22 at 13:34:20:

The wire to the starter is the hot wire.
It grounds through the engine case,the big wire to the rear on the right side of the engine is ground. Trouble ensues when it gets corroded.

Yep, figured this out, there is an insulation spacer towards the end of the wire connection.

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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 616	Re: Well, I reached the end of the line with my S4 Reply #16 - 10/15/22 at 15:11:21 Just ordered a few size o-rings from McMaster, will update this thread once I find the size that works. https://www.mcmaster.com/o-rings/system-of-measurement~metric/
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Well, I reached the end of the line with my S4 Reply #17 - 10/15/22 at 17:15:36 Clean up any marks and dings if there are any. Lightly grease it.
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och

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Re: Well, I reached the end of the line with my S4
Reply #18 - 10/18/22 at 18:28:57

Just installed a 35mm ID x 3.5mm thick x 42mm OD o-ring. Fit very snug, had to tap the starter in with a hammer, I'm sure it won't let any oil through. Will ride the bike in the next few days and update this.

This is McMaster part number 1302N604. They are sold in packs of 25 pieces, so if anyone runs into the same trouble, let me know, I'll mail you an o-ring. I have 24 pieces left. Grin

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och

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Re: Well, I reached the end of the line with my S4
Reply #19 - 10/20/22 at 11:10:47

Mike, I dont even know how to thank you enough. For several months I've been battling this darn leak, I spent over $1000 in parts and labor, and endless hours of my time... All this effort to fix what wasn't broken.

I was already considering either trashing the bike, or getting a whole new motor, the former option being heartbreaking and the later being wallet breaking.

All this just to see your post, and one o-ring and three easy to access bolts later the leak is gone. Ten minutes of work at most, and everything is bone dry. Rode it today for a few hours, came back home - everything is bone dry, no dripping.

I am a bit disappointed in the mechanic that replaced my starter, he should've known better when he didn't feel any resistance from the o-ring, but it is what it is. My baby is bleeding no more, and I'm just happy to ride it again!

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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: Well, I reached the end of the line with my S4 Reply #20 - 10/20/22 at 12:32:47 Glad to hear you outlasted the problem! I am always a bit disappointed when I hear people give up on their bikes. But then again, not everyone is up to the wrenching and tinkering to keep them running at their best.
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justin_o_guy2

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Re: Well, I reached the end of the line with my S4
Reply #21 - 10/20/22 at 15:55:42

I hope nobody goes through that much Hell to locate a leak, ever again. Sure glad you figured it out Before you did something drastic.
Now, is there anything you can say for the next guy? If you had to figure it out again, is there something you could do that would lead your eyes up higher? Find it Up There, where it came from, instead of seeing it drip off the motor and believe it was leaking there?

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The people never give up their liberties but under some delusion.- Edmund Burke.

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4184 Honolulu	Re: Well, I reached the end of the line with my S4 Reply #22 - 10/20/22 at 17:55:42 Gratifying to hear you were successful. Very glad you got it fixed.
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och

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Re: Well, I reached the end of the line with my S4
Reply #23 - 10/20/22 at 18:25:37

justin_o_guy2 wrote on 10/20/22 at 15:55:42:

I hope nobody goes through that much Hell to locate a leak, ever again. Sure glad you figured it out Before you did something drastic.
Now, is there anything you can say for the next guy? If you had to figure it out again, is there something you could do that would lead your eyes up higher? Find it Up There, where it came from, instead of seeing it drip off the motor and believe it was leaking there?

I guess sometimes you gotta think outside the box, but if it wasnt for Mike's post, I'd probably keep fighting with the cover and never discover the correct problem.

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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 616	Re: Well, I reached the end of the line with my S4 Reply #24 - 10/20/22 at 18:26:32 DragBikeMike wrote on 10/20/22 at 17:55:42: Gratifying to hear you were successful. Very glad you got it fixed. Yep, thank you so much. Hopefully someday I can return the favor by helping others.
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2689 WTF is JOG?	Re: Well, I reached the end of the line with my S4 Reply #25 - 10/24/22 at 19:55:42 So it's not the end of the line after all. More like the brink. #savedByDragBikeMike
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10603 Oklahoma Gender:	Re: Well, I reached the end of the line with my S4 Reply #26 - 10/25/22 at 07:03:15 ohiomoto wrote on 10/24/22 at 19:55:42: So it's not the end of the line after all. More like the brink. #savedByDragBikeMike 👍 💫 💥
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: Well, I reached the end of the line with my S4 Reply #27 - 10/25/22 at 10:54:54 I got the starter o-rings, OCH. Thanks a bunch!
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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 616	Re: Well, I reached the end of the line with my S4 Reply #28 - 10/25/22 at 14:00:55 TheSneeze wrote on 10/25/22 at 10:54:54: I got the starter o-rings, OCH. Thanks a bunch! Great, hope one of them works on your bike! The medium size is the one that worked for me.
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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 616	Re: Well, I reached the end of the line with my S4 Reply #29 - 10/25/22 at 14:03:04 ohiomoto wrote on 10/24/22 at 19:55:42: So it's not the end of the line after all. More like the brink. #savedByDragBikeMike Not the end at all, this bike got another 100k in it now, lol. Just gotta make sure to do Versy cam chain tensioner before its too late!
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