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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Serious Crankcase Woes! /cgi-bin/YaBB.pl?num=1499112361 Message started by jasbmo on 07/03/17 at 13:05:59 |
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Title: Serious Crankcase Woes! Post by jasbmo on 07/03/17 at 13:05:59 I decided it'd be a good idea to paint my crankcase covers, which they came out nicely (pre-re-installation). I also had a great opportunity to add the Cam Chain Tensioner (thanks Mike!)...it when I put the crankcase covers back on the bike and things got very bad... :-[ 1. Stator Worn Down - a rogue washer stuck to the inside of the magneto, and when I tried to start the bike, it made some clunking noise and green pieces of the stator came out. Do I need to replace this stator? 2. Washer Mystery - where does this go? Am I holding this near it's correct placement over this gear? 3. Clutch Pressure - I still have the clutch rod in, but once I replaced the cable, I press the clutch and there's only half the pressure, I doubt it'll even engage. What's happening here? Does the oil pressure need to build? :-? 4. Slow Oil Leak from Left Side - I place a new gasket on (OEM), but it still had a slow oil leak...when I took a flashlight to the gasket, I saw it was slightly misaligned (1-2mm higher than being flush from bottom), would this little discrepancy cause a slow leak? Bonus: the covers came out pretty good right? :) |
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Title: Re: Serious Crankcase Woes! Post by jasbmo on 07/03/17 at 13:07:21 Here's the stator, there are those small green pieces on my finger and around the actual component. |
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Title: Re: Serious Crankcase Woes! Post by jasbmo on 07/03/17 at 13:08:04 Lastly (apologies for the broken thread), here's the rogue washer. Is where it should've gone? |
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Title: Re: Serious Crankcase Woes! Post by verslagen1 on 07/03/17 at 13:37:55 676C7E6F60620D0 wrote:
not there... here... http://www.savageriders.com/verslagen/Starter%20Clutch%20Upgrade/washer-location.jpg |
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Title: Re: Serious Crankcase Woes! Post by verslagen1 on 07/03/17 at 13:42:01 484351404F4D220 wrote:
I think it's quite common for the clutch disks, wave washer not to align correctly. Loosen the spider, smack it around a bit then put it back together... worked for me. Dam spider... show it who's boss. :-? |
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Title: Re: Serious Crankcase Woes! Post by batman on 07/04/17 at 18:51:40 You can test the stator with a volt /ohm meter IT's in the Clymer manual . |
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Title: Re: Serious Crankcase Woes! Post by jasbmo on 07/05/17 at 12:14:49 293A2D2C333E383A316E5F0 wrote:
I think it's quite common for the clutch disks, wave washer not to align correctly. Loosen the spider, smack it around a bit then put it back together... worked for me. Dam spider... show it who's boss. :-?[/quote] Verslagen1 - you seem to be the answer to all my problems. What is the spider? Is removing these bolts then smacking this things around? |
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Title: Re: Serious Crankcase Woes! Post by Fast 650 on 07/06/17 at 12:08:26 392A3D3C232E282A217E4F0 wrote:
not there... here... http://www.savageriders.com/verslagen/Starter%20Clutch%20Upgrade/washer-location.jpg[/quote] On my engine that washer was on the back side of the gear when I opened it up. Did Suzuki assemble it backwards, or does it not matter which side the washer is on? |
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Title: Re: Serious Crankcase Woes! Post by Dave on 07/06/17 at 12:10:04 If your engine has the torque limiter idler gear like the one shown in the previous photo.....there should be a washer on the front and on the back......2 of them! If you engine doesn't have the torque limiter....the idler gear doesn't use any washers. |
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Title: Re: Serious Crankcase Woes! Post by batman on 07/06/17 at 13:46:12 95's had a 5 speed trans , but the torque limiter gear didn't come until 96. |
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Title: Re: Serious Crankcase Woes! Post by Steve Bobber on 08/01/17 at 10:40:24 I also found a washer on the inside sticking to the magnet. Gear is loose This issue started while riding. Heard a clanking noise in the case, motor ran but I had no drive to the belt. Is this common ? What's the correct repair I didn't find anything in the clymer. |
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Title: Re: Serious Crankcase Woes! Post by verslagen1 on 08/01/17 at 11:46:05 check your drive pulley, does it rotate on the shaft? If the splines are worn off, it will allow the pulley to turn on the shaft with a clunking sound. |
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Title: Re: Serious Crankcase Woes! Post by jasbmo on 08/02/17 at 18:19:58 In response to "batman", "Dave" and "verslagen1"... I have a 2003 (or 2002) Savage. Am I going with Option 1 (with 1 washer) or Option 2 (with 2 washers)? I didn't find 2 washers when I originally opened this up, but it could be creeping around somewhere. :-[ |
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Title: Re: Serious Crankcase Woes! Post by verslagen1 on 08/02/17 at 19:22:53 NEVER OPTION 2!!! >:( option 1 with 2 washers, 1 on either side of the gear. |
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Title: Re: Serious Crankcase Woes! Post by Dave on 08/03/17 at 03:40:21 If you choose option 2.......the rear gear will be squeezed between the cover, and the starter motor will not be able to turn the engine over. You will then have to take the cover back of.....and choose option 1. Both washer go on the front idler gear (torque limiting gear)...one washer on the inside and one on the outside. |
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Title: Re: Serious Crankcase Woes! Post by Jonty03 on 08/21/17 at 07:41:46 May I add my profound thanks for this thread...I too have followed this path and could not for the life of me work out why the starter motor couldn't turn over the engine after replacing the crankcase cover. So, a big thank you to all contributors for restoring my sanity! ;) |
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Title: Re: Serious Crankcase Woes! Post by Yoshi on 01/14/24 at 19:53:00 Should there be 2 or 1 washer in a 2006?? |
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Title: Re: Serious Crankcase Woes! Post by verslagen1 on 01/14/24 at 21:21:44 4C5D4C7579777D6E6F77751C0 wrote:
you should have 1 washer on each side of the gear splines or it will eat thru the bosses. |
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