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?  

Lastly (apologies for the broken thread), here's the rogue washer. Is where it should've gone?

jasbmo wrote on 07/03/17 at 13:05:59:


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.    

verslagen1 wrote on 07/03/17 at 13:42:01:


Verslagen1 - you seem to be the answer to all my problems. What is the spider? Is removing these bolts then smacking this things around?

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.

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.

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.  

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.