Hello everyone. I’m having trouble starting my Savage (Ryca CS-1 rebuild)

The decompression solenoid works (single click), starter solenoid works (single click) when testing the starter motor removed from the frame.
The starter is successfully turning over (I have opened the starter, brushes ok).

Just replaced the old battery with a new one, measured at 12.9 volts. Measured the ground connection (picture), ok.

When the starter motor is installed back on the bike, a single clicks heard but starter motor does not spin and will not crank the motor, headlight goes out when pressing the starter button.

The bike hasn't been used for three years.Have any of you encountered this problem before and/or have any suggestions as to what can cause this?

Thanks for a great forum!

Thank you for the reply,

The starter works in a bench test and also when connected to the starter solenoid when outside of its normal position. When mounted in place, it doesn't spin. So the solenoid is able to at least deliver current to the starter in idle.

Thanks for the tip, that might be worth a shot👍

Yeah, the hard part about a bench test is knowing how much power the starter has when spinning (other than jumping off the bench and on to your foot from 3 feet away)

So, just put the starter back and repeat the test with jumper cables bypassing the starter relay.  If strong it will spin the crank so be sure to have it in neutral.

But, while you have the starter out lets check the starter gears.  Reach into the case through the starter hole and spin the gears with your fingers.  It should spin 1 way and not the other.

If you ever had the stator cover off of a late model savage, there are a couple of washers in there that have a certain location to be and are usually placed back in the wrong location that locks the starter gear train up.  So if it doesn't spin in 1 direction I would suspect that has happened.

Thank you for the suggestions, the solution seems to be your suggestion verslagen1.

Took out the starter and tried to turn it, but the gears were stuck.

Then I loosened the screws holding the stator cover and tried again with the starter mounted and yes, the motor cranks!  Thanks again and for keeping this forum alive 👍

The old washer on the wrong gear trick!  Dave shared a good thread, but here’s a photo I saved from Youzguyz.

Note: when you pull the side cover off, you could find that washer just about anywhere in there.  The magnetization of the alternator rotor makes it hop off to various hiding places.  It could be clinging to the cover, it might still be on the wrong gear, it might be stuck to the rotor, it could be sitting down at the bottom…just keep looking.

Oh, and get a new OEM gasket for the cover.  The cheap aftermarket ones are junk and don’t seal well (trust me, I know).

Put it on the correct gear (anti-backlash gear).  Just FYI - there is another washer on that shaft on the inside (crankcase side) of the backlash gear as well.

If the washer is on the starter gear that engages with the starter shaft, it will bind.  Also make sure the shoulder on that starter gear is facing the right direction.  The shoulder side goes towards the inside facing the crankcase.  This will ensure it lines up perfectly with the anti-backlash gear.

I don’t think using sealant instead of a gasket would throw off the clearance, but the washer on the wrong gear will.

I chose to follow ThumperPaul's advice, removed the washer on the starter gear and put it on the anti-backlash gear. Mounted all together with a new gasket and pressed the starter button, and guess what: The Savage started for the first time in 3 years.

Thanks to everyone for your comments and for helping out👍

Good going.
AttaBoooy, Paul..