Multi-problemed bike (electrical + ???)

[ImaginativeFig]

I never did anything to the small gear.
All we did to that side was open it up, look for metal shavings/damage, then ordere
d a new gasket, once the new gasket came in, I attempted to put the cover on and all the cracking started. The gears are in the same order they were when I first opened it, I'd totally believe that you're right and they're in the wrong order, except that I don't see how I ever got my bike started in the past if that's so.
I'll go look for/at BadBob's teardown

[ImaginativeFig]

I'm not having any luck finding Badbob's tear down. Searched all the posts ever started by him. Some interesting ones, to be sure. Was it in the Instructional Articles? Somewhere else?
Edit: Found where you mentioned it, in clofan's post, which by the way, since I'm going to be taking the rotor off, any tips on preventing Clofan's situation would be greatly appreciated. As I'm looking at pictures and videos of how these things work, it appears his situation is not terribly uncommon.

[jonathan180iq]

http://gz250bike.com/forum/showthread.php?t=1986 - Changing the Oil Cover Gasket

http://gz250bike.com/forum/showthread.php?t=1476 - Fix a Slippery Clutch

Not exactly the same thing, but this should offer some insight. Badbob is not around anymore, but he was rather descriptive with thoughts.

[ImaginativeFig]

Clofan, who was very recently in that part of the engine confirms what Raul said, that the pair of little gears is reversed from how it's supposed to be. I'm still a little bit mind boggled on how on Earth my engine's been starting this whole time... (edit: you know, back when it had a full cam shaft)

[blaine]

It baffles me how a cover was on there tightly before with no issues.

[ImaginativeFig]

Yeah, it's not like they're loose. Haha, I had the thought of maybe one of my room mates knocked it out and put it back in, but no...
Friggin' mysteries man. I seriously can't figure out how it happened.
I wonder if my friend's friend who was looking at it in October/November did something, put the gears in wrong, and then miraculously got the cover back on w/o cracking anything? But when I asked him what he checked he didn't say anything about going into any part of the engine (or doing an oil change... but maybe that's why it had so little oil in it in January?)
I dunno. I guess I need a new starter driven gear though. Unless y'all think I'd have some luck with welding (JB or friend who welds) this one?

[raul10141964]

this is my gear after my starter clutch explode because the bolts holding it to the magneto become lost
i use a mig welder to fix it and a dreamel tool to touche up the tits
is noisy but being working for about 6 mots i planing to inspect it when i do the 6000mi oil change

[ImaginativeFig]

Well, apparently I have a minor butt ton of friends who weld, so I'm going to see if my bike shop will be so kind as to lend me a rotor puller and send the gear off to one of those friends

[ImaginativeFig]

Anyone got recommendations for taking off that flywheel nut? Suzuki's "rotor holder" tool looks like a joke (it's just a rounded Y with two screws)

[blaine]

Originally Posted by ImaginativeFig

Anyone got recommendations for taking off that flywheel nut? Suzuki's "rotor holder" tool looks like a joke (it's just a rounded Y with two screws)

A strap wrench works well.