No gasket for generator cover, now starter labors.

[Anonymous]

I had a leak in the gen gasket, so I took off the cover only to find that no place in milwaukee sells replacement gaskets for this bike. Even the Suzuki dealer claims they haven't stocked the part for 5+ years.
I decided to use Permatex Ultra Black instead. The good news is that the leak was repaired but now it seems as though the starter is binding when I try to start the bike. The battery drains almost instantly. I can get the bike started after charging the battery or jumping the bike but the starter makes a louder more laboring noise than it did just a couple of days ago (bafore I removed the cover). It used to start great.
Is it possible that the cover is binding one of the gears? I almost think that the original gasket was a spacer and that the shaft that the middle gear is mounted on is now being bound or pinched.
I took the cover off this morning and tried to turn all the gears with my fingers and everything seemes loose without the cover on, but when I replaced the cover again the starter had the same trouble.

Any tips or info on this particular problem?

I could get the gasket tape from the parts store and see if that helps, but I wanted to see if any of you folks here had any experience with this before.
Thanks in advance.

[BigMattyD]

I believe you may be right about the spacing issue, there is a protrusion on the back of the cover that acts as the "axle" for the starter gear. Perhaps there was some misalignment or binding when you reinstalled it. The good news is I found an OEm gasket on Alpha Sports.com for $7.38.

Here is their website or you could try BikeBandit.com

http://www.alpha-sports.com/suzuki_parts.htm

Matt

[SqDancerLynn1]

In an emergence use a cereal box for a gasket

[Robert Corrie]

I'l have to keep the cereal box in mind,nice thinking.

[ChuckB]

I would look at the cover on the inside for any markings that would indicate you do not have the strarter gear shaft properly seated in the cover. This would definetly cause a binding on the starter. Also most auto stores sell gasket material so you can make your own gasket..

[SqDancerLynn1]

Their should be a thrust washer on both sides of the starter gear SO YES the lack of a gasket could cause it to bind up

[Anonymous]

Thanks guys.
I was able to purchase a gasket from a local shop after much hunting.
When I got home with the new gasket the first thing I did was lay the bike down on it's side on a car ramp so it was on a 45 degree angle and loosened the screws on the cover (this way I didn't have to drain the oil too). Then I bumped the starter and the binding went away, so I figured the new gasket would do the trick. Replaced gasket and problem solved. All it needed was that 1/32 of an inch.
Thanks again.

[rustybronco]

Measure the old gasket thickness, go to the local auto parts store, buy some sheet gasket material, trace out the cover onto the gasket material, cut with a razor blade put a dye on the cover press onto traced gasket ,cut inner side of gasket, punch out holes with a ferrule (brass thing for brake lines) and VOLA' home made gasket...
I did this for my valve cover gasket, best thing NO waiting...
Next time...

[BigMattyD]

The strange thing about these side cover gaskets is that they are wider than the gasket seating area. For example, on my side covers, the gaskets extend inward an extra 1/4 to 1/2 inch. Are they all like that, or did someone maybe put the wrong gaskets on the last time it was serviced?

Matt