SuzukiSavage.com - Won't crank - what besides Auto Decompression?

thehoghunter Full Member 2004 No Login Offline Chop Suey Posts: 181 Tampa Gender:	Re: Won't crank - what besides Auto Decompression? Reply #15 - 03/10/05 at 09:37:31 Good news - I already had a 17mm socket. Bad news - just hand tightening the L/crankcase cover down causes something to make it impossible to turn the alternator rotor bolt clockwise.
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thehoghunter

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Re: Won't crank - what besides Auto Decompression?
Reply #16 - 03/10/05 at 10:07:20

Found it (I think). I replaced the alternator assy back when I first started tearing the bike apart to make all the changes I wanted to this 'winter'. The replacement I have is off a 1986 Savage. It's got one piece (the pulse generator) to it that is about 1/16 inch taller than a 1996. It's hitting the gears causing them not to move at all. Note the '86 is curved on top - the '96 is flat on top.

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thehoghunter Full Member 2004 No Login Offline Chop Suey Posts: 181 Tampa Gender:	Re: Won't crank - what besides Auto Decompression? Reply #17 - 03/10/05 at 10:50:36 ??? That wasn't it. I put my original in and I still can not turn the alternator rotor bolt clockwise once the L/crankcase cover is on and it's bolts hand tightened. Must have a slege hammer around here somewhere....
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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Won't crank - what besides Auto Decompression? Reply #18 - 03/10/05 at 10:57:49 Ruh-roh... BFH treatment is good for stress but rarely achieves desired results.
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thehoghunter

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Re: Won't crank - what besides Auto Decompression?
Reply #19 - 03/10/05 at 11:40:06

Why am I happy and mad?

Cause it's working now but I don't know what the puck changed!!!!

I took it apart two more times and put it back together again - I was hoping to crank the heck out of it the first time and cause some kind of wear/scratch or something to show where it might be hanging. Could not find a thing.

I put it back in the second time and walked away to have some lunch - didn't try cranking on the alternator rotor bolt. Come back and it turns. Tightened down all the crankcase bolts - it turns.

No one else is here so it isn't like someone else found it. I HATE it when this happens. How do I know it won't start fouling up again. I went ahead and took it back apart - put it together and it still works. So I'm going to finish putting it all together, get on it and go riding tomorrow (of course, that's if everything else goes well I guess!).

AAAAARRRRRRRRRUUUUUUUUGGGGGGGGGHHHHHHHH!!! Angry

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thehoghunter

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Re: Won't crank - what besides Auto Decompression?
Reply #20 - 03/10/05 at 16:05:06

And the luck continues.

Putting the exhaust header pipe on, another broken bolt (okay a stud but it's still broke). Can't move it with vise grips so I drill it out. Knock in a easy-out and the easy-out snaps off as I try to turn out the rest of the stud.

Anyone want to buy a used savage that use to ran really well, just leaked oil?

Is it possible to drill out an easy-out? I always though those things were made so they wouldn't break (got to stop eating my Wheaties in the morning).

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Nightrain Ex Member	Re: Won't crank - what besides Auto Decompression? Reply #21 - 03/10/05 at 16:18:42 You cant drill an easy out. Always use vise grips over an easy out, if you can get a grip on it. Youll need to heat it. Dont heat the stud but rather the part surrounding it. (heat = Expansion). I wont buy the bike but I'll take dibs on that seeger front end good luck
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Ed L. Serious Thumper Alliance Member Offline "We All go a Little Crazy Sometimes" Norman Bates Posts: 2808 Sunny Florida Gender:	Re: Won't crank - what besides Auto Decompression? Reply #22 - 03/10/05 at 16:53:34 I've had some success removing broken easy outs by getting a sharp punch and hammer and tapping on the busted easy out with the punch. Try to loosen it by tapping it and trying to unscrew it as you tap it. Use plenty of oil and some heat. They can be a pregnant dog to get out, luck on it
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10802 Oklahoma Gender:	Re: Won't crank - what besides Auto Decompression? Reply #23 - 03/10/05 at 18:32:27 Ever hear the old song they used to sing on "HE-HAW"........." if it were'nt for bad luck I'd have no luck at all". Sorry man, but I just could not resist.. I will pray for you and your Savage, it has worked for me many times.
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Max_Morley

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Re: Won't crank - what besides Auto Decompression?
Reply #24 - 03/10/05 at 20:40:37

Do you have an arc or wire feed welder. If so, find a nut that will just fit over the broken off stub. Weld the nut to the stub. It should turn out easily when it has cooled. The nut gives you someting to turn and the heat usually breaks the bond between the threads. I read in a tech tip somehwere that paraffin or a candle held agains the warmed thread will be draw in a allow the part to free up.

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thehoghunter

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Re: Won't crank - what besides Auto Decompression?
Reply #25 - 03/11/05 at 05:15:26

Thanks for the advice (and prayers)! After posting I didn't bother to work on it - as I was ready to use the sledge on it.

Don't have a welder but heard the same advice on another board about welding a nut to it. Will have to wait on this as I can't keep putting off other work to do this. Guess it will be a ornament in the garage for awhile.

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Savage_Greg

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Re: Won't crank - what besides Auto Decompression?
Reply #26 - 03/11/05 at 10:29:39

thehoghunter wrote on 12/31/69 at 16:00:03:

Sorry Ed - I don't do 'winter storage'!

snip....It has no spark but yet, I don't expect one since it doesn't seem to want to turn over at all. When I had the spark plug out looking for the spark, I never noticed the engine putting out any compression from the spark plug hole (wasn't looking for it mind you, just think I would have noticed it ).

I just tuned into this topic. Are you saying that you had the left cover off and now the engine won't turn at all with the starter or by hand?

If so, I may know what happened, cause it happened to me and in the process, I found the first "missing piece" of information in the Suzuki Service Manual Tongue

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Savage_Greg

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Re: Won't crank - what besides Auto Decompression?
Reply #27 - 03/11/05 at 10:47:43

As I read further down, I see that you got it to turn over....before the broken stud, that is. But just to continue with the first problem. Was there any chance (since you don't know), that you put this washer on the wrong starter gear? I know that when I pulled my cover off, this washer stuck to the cover ('cause of the oil) and then fell on the floor so that I had no idea where it actually went. It isn't mentioned in the manual either, and as 50-50 chances go, I reinstalled it on the wrong gear shaft. Result: locked starter.

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thehoghunter

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Re: Won't crank - what besides Auto Decompression?
Reply #28 - 03/11/05 at 11:37:22

Greg - it's possible but I know it doesn't show in either Clymers or Suzuki's manuals - but it does show it on the microfiche (although it seems as if the gears are in the wrong place - either that or my gears are in the wrong place!

) I looked it up when I first took the cover off and it fell out afterwards - there is suppose to be two washers - one on each side of the gear.

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Savage_Greg

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Re: Won't crank - what besides Auto Decompression?
Reply #29 - 03/11/05 at 11:43:23

thehoghunter wrote on 12/31/69 at 16:00:03:

Greg - it's possible but I know it doesn't show in either Clymers or Suzuki's manuals - but it does show it on the microfiche (although it seems as if the gears are in the wrong place - either that or my gears are in the wrong place!

) I looked it up when I first took the cover off and it fell out afterwards - there is suppose to be two washers - one on each side of the gear.

Yeah, but in my own little way of looking at it, I figured that one of the washers went on each gear. Wrong. And luckily, since the engine hadn't gotten hot, I was still able to save the cover gasket.....of course, since I had gotten to the point of pushing the starter button, there was a bunch of stuff to disassemble again.

Actually I have had two issues with that washer. The second one is even more embarassing. Wanna hear about it?
Tongue

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