Question about 2003 Suzuki SV 650

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Bike won't start shop told me starter clutch or woodruff key bad how do you remove the magneto to check these also the big gear behind magneto i was told is not suppose to spin freely and it does guy at suzuki said woodruff key bad thank for any help

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  • mwarej123 May 11, 2010

    Can you push start it? Does the engine turn freely?



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  • Suzuki Master
  • 3,433 Answers

With a puller, but look at it first. There should be no need to remove anything to get to the starter.

Posted on Nov 12, 2009


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Posted on Jan 02, 2017


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John deere stx38 no spark

1. check the woodruff key on the flywheel for play, 2. check the magneto with a meter to see if it is bad. 3. Check the magnet strength in the flywheel. 4.check the gap between the fly wheel and the magneto, The gap should be 010.

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My riding mower won't start, new starter spark plug and fuel filter. Now what?

You did not post any information about the motor. There is a specific gap between the magneto and the flywheel and also the flywheel has a woodruff key to make sure the timing is correct. Check for spark, check gap on magneto and check magneto if you don't have spark.

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1997 Big Dog Vintage Classic at Sturgis, SD this weekend, just quit ! He (Art/husband) is out there looking for the problem..12 volt from battery to turn on switch Nothing after that In linefuse loca

Hi, Deborah and the usual suspects are:
1. Ignition Switch not in the "ON" position.
2. Engine Run Switch in the "OFF" position.
3. Discharged battery, needs to be 12.5 volts or better and be able to pass a load test if necessary.
4. Check the battery terminals for damage or corrosion check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
5. Bank angle sensor tripped and ignition/light key switch not cycled to the "OFF" position and then back to the "ON" position.
6. Faulty ignition switch.
7. Faulty starter button.
8. Faulty kickstand or clutch pull in switch/sensor.
9. Security alarm needs a reset.
10. Starter control circuit, relay, or solenoid faulty.
11. Main fuse or circuit breaker may be blown or faulty.
12. Electric starter shaft pinion gear is not engaging or over-running starter clutch slipping.
13. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have nice a day.
What to do When Your Motorcycle Won Start
Steps to Take When Your Motorcycle Won Start Dennis Kirk Powersports Blog
Big Dog manual 2005 all models pdf

Aug 15, 2016 | Motorcycles

1 Answer

Hi!!!!! i have an kawasaki zx6r 1998 and it dosent want to start , i started it 2 days ago, but today it dosent want i charged battery, and when i push start button it dosent do nothing, i checked coil...

Check the clutch, neutral and side stand safety interlocks.
Double check that the bike is in neutral, and the clutch is pulled in when trying to start the bike.
If the bike is in gear with the side stand down, the bike cuts off all ignition.
If the clutch isn't pulled in, the starter won't engage.
Check all these safety interlock switches, and make sure you are in neutral with the clutch in when trying to start the bike.

Jun 27, 2011 | kawasaki ZX-6R Motorcycles

2 Answers

One day i was comin off the exit ramp downshifted in order to come to the stoplight. I was at a complete stop and put the bike in first gear. The engine revved as i let go of the clutch but there was no...

It will not be a bent shift fork. If the clutch lever feels the same pulling the lever in and out as it did before the problem came up then chances are the clutch is okay. Does the lever at the gearbox move properly when the hand lever is moving in and out? Is the clutch cable hanging up on something? I think you are going to find either a broken woodruff key on the gear at the right end of the crankshaft or clutch plates hanging up on the clutch hub. The broken key would prevent power from going to the ring gear on the outer clutch hub. The clutch plates can wear grooves into the clutch inner and or outer hubs. Too deep a groove and the plates can be unable to be compressed by the clutch springs. The result is no power being transmitted through the clutch. Another possibility is a broken shift shaft arm or arm spring. The right engine side cover will need to be removed so you can then do a visual inspection of the crankshaft gear, clutch hub and shift shaft lever. If I knew the year and model and engine size of your Yamaha bike I could offer more exact diagrams. The one below are generic. Go to and you can see an exploded view of your specific engine. Please rate my answer. tombones49_92.gif

Apr 21, 2011 | Yamaha FZR 600 Motorcycles

1 Answer

I just purchased a 1994 BMW K110RS was told by the previous owner that the bike had a starter clutch problem. I have stated the bike about 10 times (hot and cold). The bike starts with no hint of any...

Considering the year of the bike, I wouldn't be afraid to tackle the job, The only way to learn about it is to get your hands dirty, the dealer will only charge you about $1500, They don't make a move for any less. My buddy just took his in for spring service, because it wouldn't start, It cost him $1200 for the minor clean up and tune up. I told him I would have done it for $1150, Check it out.

Jun 24, 2010 | 1994 BMW K 1100 RS

1 Answer

I have an 86 Yamaha Virago 535. While warming up the bike, the starter button got stuck. It ran for about a minute before I realized it. Now the bike will not start. All the light turn on, etc... (new...

The starter setup on those Viragoes are not that bad to do. The only thing I don't like about it is the the pinion gear. The pinion gear is also a clutch. When they get old they can either jam or slip. It sounds like the starter is damaged. Check starting system before installing the new starter. You want to make sure there isn't a short. Replace the little clutch setup too I believe it is sold seperately.

May 05, 2010 | Yamaha XV 535 Virago DX Motorcycles

2 Answers

2004 Yamaha V-Star 1100 Silverado has problems with starting

Sounds like the starter clutch is slipping and or beginning to fail. You should take it back and have them inspect the starter clutch for scoring or damage.

Sep 16, 2009 | 2006 Yamaha V Star 1100 Silverado

1 Answer


It is not a big job if you know what to do and you have a rotor puller. But you may likely cause big $ damage if you don't.
The "starter clutch" is on the end of the starter motor and when activated turns an idler cog, which then turns the clutch starter set. This clutch starter set is behind the magneto rotor (flywheel) and should not be the problem. To remove the rotor you will require an appropriate size rotor puller available from most larger bike accessories stores for under $20, or the Suzuki Special Tool for 10x the price!
Your problem most likely lies with the starter clutch pack itself and is a parts replacement item.
The link below will provide by exploded view, diagrams of the parts you need to check, at least you can have an idea when you talk to your parts dealer. Cheers.

Jul 11, 2009 | 1991 Suzuki DR 650 RS-E

2 Answers

Crankcase pressure

which seems to have solved the problem I had with the bike jumping out of 5th gear. Now on the not-so-good side. I now seem to have very high pressure in the crankcase enough to spray oil out of the channel that links the generator (rotor) area with the gearbox and coats the rotor and stator with oil. Its as if the oil isn't being picked up properly or maybe if the oil runs through one of the gearbox shafts - do I have to align the oil feed hole in this with something? This was the one thing that I wasn't certain about when I rebuilt the gearbox.... would this cause the problem? I can't find any crankcase breathers that could be blocked so I assume the bottom end vents up the channel for the timing chain, and then out the top camshaft cover and the thick black pipe on the top (which is clear). ,Either you have excess blowby or a passage somewhere is blocked. Leak down test first, then its back to removing covers until you find whats blocked,,,

Nov 10, 2008 | 2006 Bajaj Wave

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