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/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Got The Drive Pulley Blues! /cgi-bin/YaBB.pl?num=1185827428 Message started by Rogue_Cheddar on 07/30/07 at 13:30:28 |
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Title: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 07/30/07 at 13:30:28 Got my new Maxxis Classic Tires and EBC brakes front and back from Biker Bandit. Around $218 total. Check around stealerships for mounting and balancing. I was going to do brakes myself. Cheapest was $45 a wheel if wheel off the bike, so I stay up at night and pull my wheels. When I pick up my wheels the guy says I should have my wheel bearings done. How much is that I ask. $75 bucks a wheel plus bearings total $225. I says I'll think about it, Shopped around and got them done for $148. Then I spent a few days trying to polish wheels and spacers and stuff. Took frickin forever, I'll save spokes for winter down time as it was just taking too long. So I start putting all my stuff back together and am feeling really psyched because the bike is gonna look awesome with the new tires and stuff, when I was putting the drive belt back on and spun the rear tire a little, I heard a noise coming from the front pulley. I had a sick feeling in my stomach, and sure enough the pulley was loose and totallly bunged. I had replaced my belt about 3000 miles ago. I had torqued that sucker down to 80 pounds and the lock nut was bent over but apparently not enough as it had backed out. I'm definitely slapping myself for not checking more thouroughly. The wife who had been riding on the back said she thought she heard some noise but I never did. The driveshaft looks questionable as it is bunged some also, I won't know if it will hold up until I get a new pulley. My question is, do you think a new pulley and maybe some judicious use of a tube of Liquid Metal, that it all might hold together and not slop around. I can't even think of what it might cost me to have the driveshaft replaced. It's not something I really want to tackle. Unless no real special tools are required and some of you think it's easy. BikerBandit: Drive Pulley Oil Seal (needed replacing anyway as it was seeping oil). O-ring Locknut $101 This I can do. I'm ordering the parts today. Driveshaft $93 replacement Labor? No idea. I'm bumming now as the bike has been down for a week already and now this. Stupid #$%^& goldang son of a blankety heck! |
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Title: Re: Got The Drive Pulley Blues! Post by srinath on 07/30/07 at 21:06:12 Find a new shop - this is why ... Wheel bearings are generic - I routinely pay $5-10 for one, neck bearings are called taper bearings and they run 15 or so each, recently swapped out swingarm bearings. Needle bearings - $8+5 shipping and inner race was $8 and 5 shipping. I dropped a GS500 race in there. To install any of those, I'll charge a 6 pack of decent brew. Removal is 5 beers, installing is the 6th. The swingarm beairngs are the hardest to get out and hardest to install, neck and wheel bearings just need a good punch and a good hammer. Pulley if the spline is OK reuse it. The transmission drive stub shaft will more than likely be fine. Its hardended steel. Oil seals are also generic items, and dont cost more than $2-5. Cool. Srinath. |
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Title: Re: Got The Drive Pulley Blues! Post by Reelthing on 07/30/07 at 23:31:35 h3ll I'm confused - had a lose front pulley my self that ate it self - around $50 for a new one - dinged the output shaft a little but not much - look here - http://suzukisavage.com/cgi-bin/YaBB.pl?board=RubberSideDown;action=display;num=1130022642 |
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Title: Re: Got The Drive Pulley Blues! Post by Carl on 07/31/07 at 01:05:31 Hi I have just had the same problem and Fitted the new pulley with Plastic Steel, Provided that the Pulley is not too loose and wobbling about on the shaft, it should be OK. I have done 3000 Miles on mine since replacing the pulley and checked it last weekend when it was all OK Regards Carl |
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Title: Re: Got The Drive Pulley Blues! Post by Savage_Rob on 07/31/07 at 05:11:56 Guess I should take a peek at mine soon. I haven't heard any noise but checking should be pretty straightforward and worth the small effort. |
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Title: Re: Got The Drive Pulley Blues! Post by Reelthing on 07/31/07 at 05:35:12 clue seems to be it makes more noise when you let off the throttle going slow - just rolling |
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Title: Re: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 07/31/07 at 11:04:56 Carl wrote:
This is encouraging, as I'm hoping Liquid Steel or Plastic Steel will help alleviate any deformity of the splines on the driveshaft. This painful lesson just proves that if you're going to do you're own mechanical work, try to be more thourough and methodical as any good shop should be. Which means check the torque on the nuts and bolts occasionally. I mean me of course , not anybody here that may have suffered a similar problem. |
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Title: Re: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 08/13/07 at 08:16:41 Well my repair did not hold up. The new sprocket started rattling after a 30 mile ride. I retorqued it down again but the nut keeps ratcheting loose after a few miles. The liquid steel just turned to powder. It appears I'm due for a new driveshaft. Does anybody here know what's involved and how much I should expect to pay for the repair? The driveshaft itself lists for about $93 on BikeBandit. |
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Title: Re: Got The Drive Pulley Blues! Post by Rockin_John on 08/13/07 at 10:02:06 Well that just sucks... It ain't pretty, that's for sure. That job is going to be expensive on several accounts: The labor is very high; because it is a total engine and transmission remove; teardown, with crankcase split, rebuild what needs it, and re-install engine/trans. That's bad enough, but as you found with the wheel bearings, any time you are that far into something, you need to do everything you can while you have it torn down. Every other gear, bearing, shim etc... etc... needs inspection for R&R. You sure don't want to pay the labor to go into it twice because of some $5 bushing that wasn't replaced the first time. And all those little $5-$10 seals and bushing start to add up. You need to search around for a local independent shop with a good reputation. They might be able to make the cost bearable. Any authorized dealer is going to break it off in you on this kind of job. Otherwise, your options are to DIY if you have the time, tools, ability and inclination. Or... find another engine/trans, Or... sell the bike whole, or part it out yourself. Sorry to be the bearer of such lousy news. This is one continuous problem with low-end bikes, or cars, or boats... whatever. It only takes a repair representing a minor percentage of the vehicle's value to turn it into a parts donor vehicle. If it was a $15k Harley, or something else, there would be no doubt about doing thousands of dollars of work to get it back on the road. |
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Title: Re: Got The Drive Pulley Blues! Post by Carl on 08/13/07 at 12:52:42 Thats Real Bad Luck, Did you Use Devcon A Plastic Steel which is the Original and Best or a Copy. Also Did you leave it at least 16-24 hours after Tightening to Set off Correctly. My Repair is still holdig up OK after 4000 Miles (I Checked on the weekend and it is OK) Regards Carl |
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Title: Re: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 08/14/07 at 08:00:18 Thanks for your replies. The pricing that I'm getting from dealers is for 8-13 hours labor at 75$ an hour. (yeesh!) :'(. parts are going to be another $200. I'd be basically buying my bike all over again. I'm going to give it another shot with some other epoxy weld products before I give up. If that fails then maybe I might try to fix it myself over the winter. I just can't justify that kind of expense. :'( :'( :'( :'( :'( |
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Title: Re: Got The Drive Pulley Blues! Post by Savage_Rob on 08/14/07 at 10:48:16 Watch eBay and the Marketplace for another engine. |
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Title: Re: Got The Drive Pulley Blues! Post by LANCER on 08/14/07 at 11:53:14 I have a drive pulley and drive shaft for a good deal. If you are interested send me a PM. |
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Title: Re: Got The Drive Pulley Blues! Post by T-Mack1 on 08/14/07 at 13:42:16 Don't forget to bend the locking washer so that the nut doesn't turn. About $1 for the washer. Item 39 on the parts micro fische. 39-1 WASHER (25X40X1.4) 1 09167-25019 (replaces 09167-25014) or 39-2 WASHER (25X40X1.4) 1 09167-25019 |
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Title: Re: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 08/15/07 at 09:57:49 LANCER wrote:
Thanks Lancer for the offer, I'm going to try another product called J.B. Weld that looks a lot stronger than the Liquid Steel putty that I tried. If that doesn't work out, I may be talking to you. I just don't have any extra funds right now. |
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Title: Re: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 08/15/07 at 10:00:16 T-Mack1 wrote:
I replaced the lock washer also, I will try to do a better job of wrapping it around the nut when I try the JB Weld filler this week. I think I need to let it cure longer. |
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Title: Re: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 08/15/07 at 10:05:02 Carl wrote:
Hey Carl, on your repair, did you apply the putty to both the shaft and inside the pulley? How did you try to remold the splines? Are you concerned about being able to remove the pulley at some point? I shouldn't have to remove mine for a while because I replaced the oil seal and o-ring, unless my drive belt gets ruptured. Only have about 3500 miles on this belt. |
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Title: Re: Got The Drive Pulley Blues! Post by T-Mack1 on 08/15/07 at 10:19:53 JB Weld, 15-24 hour cure before use. http://jbweld.net/products/instruct_jbweld.html May want to wait 24 or more. I've used it before and it seems to get super hard in a day or two. I haven't tried it on such a stressful application, but.... thier website sort of says you can. Maybe one of Engineer types could look at the spec's??? http://jbweld.net/products/jbweld.php |
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Title: Re: Got The Drive Pulley Blues! Post by Carl on 08/16/07 at 00:25:01 I Carried out my Repair as Follows. 1. Shaft & New drive Pulley Cleaned with Thinners to Remove any grease or oil 2. Mixed Devcon A Plastic Steel (This is the original plastic steel and the only one I have found that works as advertised) 3. Interior of Drive Pulley Coated with Plastic steel (Splines Filled) 4. Pulley Fitted and Immediately Tightened up with Air Hammer and the Lock Washer Bent over 5. Waited 24 Hours before Moving anything. Since the Above I have put 4000 Miles on the Bike and the pulley is still OK Hope this helps Regards Carl |
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Title: Re: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 08/16/07 at 09:41:06 Thanks Carl, that's pretty much what I'm doing less the air hammer, only have torque wrench. The JB Weld indicates a 3900 + PSI hardness factor and resists temps up to 600 degrees. These specs are the best I can find for similar products locally. I got my fingers crossed. I'll let you know how I make out after this weekend. |
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Title: Re: Got The Drive Pulley Blues! Post by justin_o_guy2 on 08/17/07 at 02:38:42 I have been using epoxies for over 30 years. Duro sux mightily & Devcon is the best I've seen. As good a reputation as JB weld has, I would go with Devcon in a heartbeat. |
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Title: Re: Got The Drive Pulley Blues! Post by Rogue_Cheddar on 08/19/07 at 18:04:19 Eureka! (you don't smell so good yourself) :D :D The wife and I put almost 300 miles on the bike this weekend and the JB weld repair seems to be working! I'm frickin ecstatic! (avert your eyes while I dance the Funky Chicken). I thought for sure the bike was done for. There was no way I was ging to get the driveshaft repaced any time soon. Thank you all for your help and comiseration. I hope this is the end of any major problems for a while and just get to enjoy the rest of the season. ;D ;D |
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Title: Re: Got The Drive Pulley Blues! Post by Rockin_John on 08/20/07 at 02:54:18 I sure hope that "repair" holds up for you, but I wouldn't ride any roads way off in the middle of nowhere without a cell phone in my pocket on a bike with a fix like that done to it! The chances of it letting go increase exponentially the further you are from home and help. ;D :-/ |
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