Bike wont start after changing the Generator cover..

[louisianagz]

I have a 2009 gz that has been sitting for about three weeks waiting for me to replace the generator cover. Finally got it (along with the stator) replaced yesterday. Gave the gasket goo overnight to set and tried to crank her this morning, nothing. Starter just clicks. Hook it up to a car to jump it off and it starts to turn over very slowly. A few minutes later it just clicks again. Just one single click. Doesn't seem like jumping it off is helping. I did move one gear inside the motor that slid loosely in and out to remove some debris from behind it, but pushed it back into its original position before replacing the cover. Is it normal for the battery to be completely dead after just 3 weeks?

[Rookie Rider]

If the battery isnt very new then i would say yes, the battery may be completely dead. Charge it up over night.

[louisianagz]

Thanks for the reply. Just paranoid that there might be something I might have overlooked that was supposed to be in a certain place or something..

[blaine]

Sounds like your battery completely dead & you had a bad connection when you were trying to boost.If you had a good connection,than it should have turned over.
:cool: :)

[louisianagz]

Cool, thanks again y'all. Took the cover back off last night and cleaned the starter gears. Reinstalled everything and it turned over fine, didn't run it for lack of oil.. got up this morning and went to get my key, damn thing would hardly turn over this time. Borrowed a charger from a buddy at work to hook up tonight... otherwise, is it possible to have the cover too tight and it may be against something? THANKS AGAIN for any responses, I'm having gz withdrawls here lol

[blaine]

Cool, thanks again y'all. Took the cover back off last night and cleaned the starter gears. Reinstalled everything and it turned over fine, didn't run it for lack of oil.. got up this morning and went to get my key, damn thing would hardly turn over this time. Borrowed a charger from a buddy at work to hook up tonight... otherwise, is it possible to have the cover too tight and it may be against something? THANKS AGAIN for any responses, I'm having gz withdrawls here lol
I think your battery just needs a good charge over night.
:) :cool:

[Rookie Rider]

Hey, i said the same thing, :o/

[blaine]

Hey, i said the same thing, :o/
:biggrin: :cool:

[louisianagz]

Lol I hope so :/. Y'all definitely make it seem like I'm worrying for nothing lol. Well, off to give it a shot..

[alantf]

Don't forget - charge it at no more than 2 amps. Preferably at 0.75 amps (Suzuki spec) A charger specifically for bikes, or a battery tender, is preferable to one designed for car batteries, plus, they're cheap enough to buy if you haven't got one already. :)

[louisianagz]

Thanks alan, I charged it overnight on 2A and it did nothing this morning. Noticed the charging recommendations on the battery this morning finally.. Definitely need a different charger lol. Brought the battery to be tested and its bad :/. BUT when I loosened the bolts to take the cover off I tried it and it turned over.. I'm thinking my homemade gasket job came out too thin and the cover is putting the starter idle gear in a bind. I notice there isn't much room at the end of the pin it slides on and both the gear and the hole in the cover for the pin are fluch with thebedge of the cover/motor.. any of this make any sense to anybody? Lol

[blaine]

:/. BUT when I loosened the bolts to take the cover off I tried it and it turned over.. I'm thinking my homemade gasket job came out too thin and the cover is putting the starter idle gear in a bind. I notice there isn't much room at the end of the pin it slides on and both the gear and the hole in the cover for the pin are fluch with thebedge of the cover/motor.. any of this make any sense to anybody? Lol
Yep.Makes perfect sense if you used wrong gasket letting the cover go in to far.
:) :cool:

[mrlmd1]

Do you see marks on the inside of the cover where the starter binds on it? Hard to believe the tolerances/clearances in there would be so tight.

[louisianagz]

No don't notice any marks.. its not the outside of the cover that I'm talking about, but the outide lip of the holes for the pin squeezing the very center of the gear. I think. Maybe. Thanks for the reassurance Blaine lol. Got a sheet of gasket material to cut one for it. Gonna try it out today

[louisianagz]

Can't figure it out. Is there supposed to be oil in the left side cover?

[blaine]

Can't figure it out. Is there supposed to be oil in the left side cover?
Yep,There should be a little! :)

[louisianagz]

Lol this is driving me nuts. I changed the the stator that came with the cover I brought. When I put my old one in, she fired right up, ran for a second, smoked a little bit and died. Now just turning over again. No combustion.

[blaine]

Lol this is driving me nuts. I changed the the stator that came with the cover I brought. When I put my old one in, she fired right up, ran for a second, smoked a little bit and died. Now just turning over again. No combustion.

It's starting to sound like the flywheel is not seated properly on the crank.(rubbing on cover) & moves enough for the "firing" to be off,so bike can't start.
:??: :cry:

[louisianagz]

How can I tell if its not seated right? Thanks for tolerating me btw :/

[blaine]

How can I tell if its not seated right? Thanks for tolerating me btw :/

Check to see if there is any play between flywheel & crank.The key in the keyway may have broken allowing the flywheel to move.
:) :cool:

[louisianagz]

Cool thanks man. I'll be able to mess with it more tomorrow while I'm off. If it moves at all then somethin is wrong?

[blaine]

Cool thanks man. I'll be able to mess with it more tomorrow while I'm off. If it moves at all then somethin is wrong?

If there is any play backward & forward than the Woodruff key is likely broke in the keyway.
:)

[louisianagz]

Welll got out there this morning and turned her over for the hell of it. Started right up and died after a little while. Brought out to sit in the sun for about an hour and a half, went back out, did the same thing. Took the cover back off and, sure enough the gear behind the starter rotor does wiggle back and forth.. Just to be sure, that is what you're referring to as the flywheel? And the Woodruff Key is what the manual calls the Generator Rotor Key? You have been a great help Blaine, thank you very much!

[louisianagz]

Another dumb question.. How on earth do I lock the shaft to get the rotor nut off? :/

[blaine]

Another dumb question.. How on earth do I lock the shaft to get the rotor nut off? :/
A strap wrench works best.Less chance of damaging the flywheel.
:) :cool:

[blaine]

Welll got out there this morning and turned her over for the hell of it. Started right up and died after a little while. Brought out to sit in the sun for about an hour and a half, went back out, did the same thing. Took the cover back off and, sure enough the gear behind the starter rotor does wiggle back and forth.. Just to be sure, that is what you're referring to as the flywheel? And the Woodruff Key is what the manual calls the Generator Rotor Key? You have been a great help Blaine, thank you very much!

Yes.The gear its self may have a little play.It's the flywheel (rotor) that can't have any play in it.It is locked in place by the key so there is no movement.
:)

[louisianagz]

Oh ok. That part doesn't move. I have searched through the forum and the manual, but can't find a way to check the timing to see if everything is lined up right. I noticed in another thread you said something about the timing being set by a pickup coil I think it was, but is there a way to see if it needs to be replaced?

[blaine]

Oh ok. That part doesn't move. I have searched through the forum and the manual, but can't find a way to check the timing to see if everything is lined up right. I noticed in another thread you said something about the timing being set by a pickup coil I think it was, but is there a way to see if it needs to be replaced?
There is a way to test the components,but I'm not good with electrical.The firing is partly controlled by the position of the flywheel.That's why if it was loose or key sheared off,the firing would be altered.That & the rubbing on the cover had me thinking flywheel moving.
:) :cool:

[louisianagz]

The rubbing I was concerned about was the case being too tight on the gasket and not allowing the idling gear (right next to the starter) to turn. It wasn't turning over at all when I used my homemade gasket crap. Now it turns over fine, even hits and runs very rough for a little while. I think I noticed some odd smelling smoke coming from the (airbox?). But it'll run for a little while then shut off and not start again. Let it sit for a while and it will do it all over again. Getting pretty aggravating lol :/

[louisianagz]

But there is no sign of the the flywheel or anything rubbing against the inside of the cover..