Starting problem with my suzuki s bandit 1998

big biker · L Plate Warrior Joined: 04 Jul 2011 Karma :

Hi I hope this I am correct with this, I am a new member and the rules are quite daunting, place in correct place, check your spelling, think or your khama etc etc, well here goes.
I have a suzuki bandit s bandit 1200 1998, it failed me at the weekend, thought it was the starter motor, when removed I held it in my hand and tried it, it seemed to work fine, felt inside the hole for the ring gear to check this, I think this is where I have a problem, something feels loose and incorrect here, does the starter engage another cog/gear to engage the ring gear, I feel inside and turn a cog/gear that is very loose and not engaging the ring gear, as I see it I need to take off the side panel but clearly would like some advice as I see a gasket and know the clutch runs in oil, so if I remove this side panel will I need to drain the whole engine oil, I would need to order another gasket. Can anyone offer some advice.
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Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

When you say "failed me" what do you mean exactly?? starter spinning and nothing happening??
The starter clutch cover does have oil behind it, if you can lean it over against a wall or whatever you can minimise the loss, it's almost guaranteed you will need a new gasket for it. It's not unknown when you have the cover off to find the centre bolt loose and the starter clutch spinning on the taper.
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big biker · L Plate Warrior Joined: 04 Jul 2011 Karma :

Sorry should have been more specific, I could not restart the engine after a long ride I push the starter button, I get a spinning noise but the engine does not turn, so I assumed the starter had gone, took it off and held it in my hand, the relay worked fine, there is little or not play in the starter shaft, the starter turned fine when the starter button pressed, the teeth are all fine and the mileage is currently 20000. I have had the bike a few weeks and have had no problems with starting what so ever, I had it serviced before I started to ride it. The bike will start with a push. Do the starter teeth act directly on the ring gear or is another gear.cog involved.
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Gary SuperSprint · Borekit Bruiser Joined: 26 Aug 2008 Karma :

Hi, if you take the clutch cover off u will need to drain the oil first. A new gasket is not essential a lot of people just use instant gasket on the covers. Before you start taking the engine to bits have you checked all the simple stuff? I've heard the majority of bandit starting problems is the condition of the spark plugs, when were they last changed? Have u checked they are all producing a spark? In some case the plugs will spark when checked but fail to produce a strong enough spark under compression. Try a set of iridium. Have u checked the carbs over, choke operation, etc. Is fuel reaching the cylinders?
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honda cub 90 (stolen), Honda nsr 125 2001 (stolen), present : fully restored honda ns 125 f 1989. Current project, susuki rf600.

big biker · L Plate Warrior Joined: 04 Jul 2011 Karma :

I had the plugs changed at the service, it will start with a push but not with the starter button, once bump started ran fine as usual, carbs inspected I was told and mixture and settings I was told are fine, indeed when running I have no issues, it idles well at around a 1000 rpm, and has not missed a beat so far. I will drain engine oil if and when I remove the side panel. Just wanted some discussion around the starting issue as the bike is stranded at home due to starting issue.
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kestrel · Nearly there... Joined: 04 Sep 2006 Karma :

Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

This is the starter clutch 'fiche, the gear on the end of the starter engages with no 1 then the main ring gear, the nut shown is the one that can come loose and lets everything spin on the tapered shaft. If you do take the cover off and everything is loose on the shaft smooth if with emery/wet & dry then loctite fhe shaft and the nut which should be torqued up to 150nm. It's better in the long run to use a proper gasket not sealant as there's always the chance you squeeze the excess into the oilways which will cause problems in the future.

https://www.alpha-sports.com/spst/1998%20GSF1200S/56.gif

One last thing before you start stripping, your battery is good I take it?? make sure by using a jumpstart just to prove beyond doubt it isn't lack of cranking power.
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I used to be indecisive but now I'm not quite so sure.

Bandit1200 · L Plate Warrior Joined: 09 Jul 2011 Karma :

i also have a 1998 Bandit 1200. i am currently installing my second starter clutch. the starter spins but will not turn over. it is probably the one way bearing on the clutch. look on Cheap Cycle Parts.com. they have the best price. just to say, you will need a rotor puller. it will be around 35.00. look on ebay. and a clutch holder to reinstall. either fabricate one or have a friend make one. sorry to say but it will probably happen again. and get a new gasket. the old one will leak. when installing the cover. make sure it slides into place easy. do not force it. i found out the hard way. cracked the cover and broke the flywheel. it is not a hard job if you get these tools. good luck and keep us posted on how it goes.

big biker · L Plate Warrior Joined: 04 Jul 2011 Karma :

Thankyou all for your replies. Indeed it was the large nut on the end of the clutch assembly, if thats the correct description. tightened it and now starts, sadly have to report that upon draining the engine oil the sump plug almost fell out, the threads have been crossed and peeled off with the sump plug nut, so I will now have to look for a new sump and a new plug so still off the road, will go and have a word the the biks shop who serviced it tomorrow though.
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big biker · L Plate Warrior Joined: 04 Jul 2011 Karma :

Could you explain helicoil please, I understand tapping hole to a bigger size, just not sure about what a helicoil is.
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Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

big biker · L Plate Warrior Joined: 04 Jul 2011 Karma :

Hi again and continued thanks for all your support. Well I have learned a lot about bandits over the last few weeks. So an update, bike now starts fine as nut that is at the centre of the starter gear now tightened but will have it checked again soon, the threads on the sump will be fixed next week, used an older sump plug that is a little longer and lots of PTFE tape and managed to get it to hold oil and not leak, have ordered new seals and exhaust manifold bolts as the ones on the bike are shot and rusty, so that I can get the exhaust off and fix the sump with a helicoil. Well don't doubt with current form that some of the manifold bolts will be a nightmare but well just have to keep putting it down to experience.
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