Gwbarm

At 145 your compression valve is not working, mech is right about the 85-90 # , maybe it didnt get back together right after the rebuild, I would still think the starter should turn it over, if you put oil down in the cylinder does that help it turn over at all,

Magnets are a problem everyone has with this machine the replacement flywheel has internal magnets, I don’t think as you said that was the initial problem, it possible they went into replace the neutral switch gears fell off everywhere and didn’t get it back together right. When I get it all back together I will check the shifting before I put the cover back on to make sure everything is moving and shifting right. So far I don’t see any major problems, haven’t got to it today very hot heat index is supposed to be 110 today

I did see that grove, at first I thought it was for a keeper, but the exploded diagram didn't show one. I guess we will find out when I get it pulled off. Thanks you for all your help.

Better Photo of the shaft from the service manual, gear just must be jammed on there. Just saw your most recent post, I thought the two gears went on to the cogged area and the smooth surface went into the bearing, and the change fork went on the bushing with the oil hole, but the gear does appear to have a bushing in it.

Forgot to answer your question yes they both free wheel until engaged with the dogs

Thats a good one and for free, it will be interesting to see your progress. Welcome!

Thanks for the reply Mech, im feeling kind of stupid right now trying to get this thing off, but I don't know how he put it on, I got an inspection mirror to look behind the gear and there is something there it doesnt look like a snap ring like the other gear has, looks more like a washer solid all the way around. I was just about to get a puller and pull it off the shaft and thought I better double check, don't want to break anything. So I looked up the diagram to see how it s supposed to be together gear number 4 is the backward gear it does not have a lock ring like the gear in front of it and that snap ring is in place, diagram does show a washer between #4 and #5 which is what I must be seeing behind the gear, so I see nothing that is locking it on. It will not budge or hasn't budged yet, I should say. Just wanted a second opinion here, you think I should go ahead and pull it off with a puller. Not sure why but all the videos I have looked at showing this gear it just slides right off, I thought maybe there was a little different taper in the gear itself from front to back, and putting it on backwards may have caused it to stick.

I like the Safari has a good mileage range top speed and price is not far fetched.

Shoulnt that backwards gear just slide off the shaft. It seems to be stuck on there. Im trying to put it all back together right to try and figure out what was initially wrong when they took it apart.

I can get the driveshaft to turn now both front and rear. IMG_3931.mov I did notice the gear on backwards, jacking it up helped because I didn't have one gear fall out of place, but I did have to drain the oil, guess I didn't jack it high enough, did not notice the bearing, thanks for spotting that, although I am going to try to locate another cover for it this one is bady cracked, I know I can fix it with JB weld but while in in here im just going to replace it, .Get a new rotor turn the gear around and try to figure out what happened to cause him to open the case, also check the neutral switch, it wasn't working, and its inside there too. It doesnt look damaged.

Finally got it off it was just stuck probably to the bearing like you said, I ended up getting 2 pry bars on each side of the case and pulling alternately and then at the same time and it finally popped. I don't like being that rough with the gasket surface, no choice here, I even tried a slide hammer with bolt screwed into the pull rope mounting holes and was afraid I was going to strip it out, I was pulling hard. This is exactly how it came out, im surprised it ran at all, magnets everywhere. Another green gasket tell tale sign somebody's been messing around. One of the cleanest engines I have taken apart in a while. Notice there are only 2 magnets left on the flywheel and they are loose. Everything else looks good, still messing with it , I just came in to cool for a few minutes, heat index here is 105 today a little better than the 108 yesterday. Further update later.

My Suzuki was etched into the rear downtubbe one I cleaned the dirt and rust away I could read it

Welcome capt , hope you enjoy it, great site with a lot of activity, posts actually get responses, unlike other sites I have been on.

Worked all morning trying to get the case off, went through the manual to see if there is any bolts I forgot, and there wasn't, while looking for forgotten bolts I found a more prominent crack. Still not sure whats holding the case on, I have gotten rough with it and still not coming off, got the top separated about half inch but bottom is not budging. Just for the record, im not having fun, heat index here yesterday was 108F.

I total agree with KP definitely the best one online, lots of activity and interesting content with lots of friendly people willing to help.

thanks for the info, I haven't seen that happen.

Just about got it read to pull the side cover off,and as I was undoing the last bolt I heard something inside the cover it actually sounded like metal reconforming after you take stress off it, and as I started looking closer it looked like the cover had been hammered on and not with a rubber mallet . It actually looked like it had been hammered on with a claw hammer, it will be interesting to see what I find in there, I was beginning to loose light and really need to see this in the daytime.

Changed the oil again today on the Big Bear dosent look like pond water anymore, it does look darker than I expected this oil probably only has 1 hr of running on it, if that much, pretty dark, so im getting the engine interior cleaner. I put in the Castol Actevo, Im going to run that for a while to finish cleaning things up and then change to Yamalube. For those who didn't catch the beginning, when I got this bike the engine was stuck and had no plug in it, and very little oil, if you want to call it oil, very green looking.

I use little magnetic bowls to keep things organized and labeled as I take things apart, one for the case bolts , one for each clutch bolts set etc. They work good so if you drop them or turn them over bolts don't go everywhere.

I think I saw a manual for that on manuals lib.com

You have checked everything, it does act like a timing issue, if stator and CDI are a mismatch that could cause a timing problem, example if new pickup coil is not putting out the right voltage to the CDI, it could be sensitive to that, you can check the voltage its putting out by using a peak voltage adapter for your meter, I kind of doubt that's what it is, you are getting a good spark.. I would check to make sure piston is actually at top dead center on the firing stroke. Also put your hand over the carb intake while cranking to feel if you have good suction and no weird feelings there.

If no power is getting past the switch, my first thought is the switch is not working.

It will be nice when you get it all together, looks good, just needs some work, and a pressure washer.

Glad to hear everything is ok, I figured you were alright, still thinking about getting the honda fixed, these things are habit forming.

What do you have so far? Do you have power, does you neutral and other dash lights work, does starter function by pushing the button. If all of this is working you should check your key switch, start/stop switch, check that you have 12 v and ground at cdi see if you have 12v going to coil.