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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Drive belt snapped ! /cgi-bin/YaBB.pl?num=1292902465 Message started by MaxMayhem on 12/20/10 at 19:34:25 |
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Title: Drive belt snapped ! Post by MaxMayhem on 12/20/10 at 19:34:25 Well the unthinkable has happened. My drive belt snapped while going about 35kmph around a roundabout on the way into work this morning. New belt arriving tomorrow morning ($325.80) :o My question is, I could not find anything in tech section or anywhere else in forum about changing the belt. Please no comments about going to chain. :) I assume all I need to do is remove front cover, side cover, left suspension, right brake cable from wheel mount, then loosen rear wheel and push in towards handle bars as much as possible and put on new belt and reverse all the above? I will bring in my camera and post a shot of the belt for the interested. I'm major time pissed, as it is the original belt and bike only has 27,000km's on the clock. It has snapped almost straight across the belt. There are a lot of cracks running across the width of the belt all the way around it on the non-toothed side. Almost like it got super dry and began cracking quite deeply. Any suggestions for preventing this happening on the new belt which cost the same as my weekly mortgage repayments :) Any helpfull comments will be very appreciated. |
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Title: Re: Drive belt snapped ! Post by Max_Morley on 12/20/10 at 20:34:14 It is going to be difficult w/o the belt in place to hold the drive pulley to get the nut off there. It has to come off to get the belt past the flange on the pulley. Maybe the old belt around the pulley and what we call vice grips (adjustable locking pliers) or C-clamp, clamping the belt together and wedging it again the swing arm. May be able to do it if you have access to an air impact wrench w/o the belt to hold, if you have a pair of heavy gloves to hang onto it with. Bummer as very few have broken over the years I've been on this board and the previous one in Germany.Max |
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Title: Re: Drive belt snapped ! Post by justin_o_guy2 on 12/20/10 at 22:28:49 The pulley on the engine has to come off. |
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Title: Re: Drive belt snapped ! Post by stinger on 12/21/10 at 00:02:10 Ill tell you what is a bummer! I have one in still pretty good condition I would have given you. |
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Title: Re: Drive belt snapped ! Post by Boofer on 12/21/10 at 08:28:45 Just a shot in the dark. What kind of chemicals, such as battery acid, cleaners, etc could have come in contact with your belt? Don't want it to happen again. Then again, sometimes you just get a bad part. Sorry. |
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Title: Re: Drive belt snapped ! Post by MaxMayhem on 12/21/10 at 14:29:17 081711160B0C3D0D3D05171B50620 wrote:
After putting belt up against the pulley I must concur. No way around it. I assume once nut is off the pulley slips off, then fix belt on to it, and put pulley back on? Boofer - No chemicals to my knowledge anywhere near my bike. Just my luck to get the last one on a friday afternoon from the production line :) Stinger - That would have been awesome but with a 6mth old son that the wife has to wake each morning at 6am to take me to work in the car, the bike needs to be back on the road asap. Max_Morley - I get what you mean I think, that the pulley will simply spin around while trying to remove the nut. I still have old belt here so may try the old-belt-around-the-pulley-while-holding-the-belt-with-gloves trick if needed. |
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Title: Re: Drive belt snapped ! Post by verslagen1 on 12/21/10 at 14:41:28 That nut is really torqued on there and it'll take more than a pair of gloves. Park it in gear against something solid. Wrap the belt around the driven pulley and clamp the end in place so it'll stay engaged or tuck it under the other side. That and the biggest breaker bar you got and it should break free. |
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Title: Re: Drive belt snapped ! Post by justin_o_guy2 on 12/21/10 at 14:44:16 I assume once nut is off the pulley slips off, then fix belt on to it, and put pulley back on? Key Wrecked You can use the old belt, run it behind the pulley & get it spooled on it, put some grips on the belt, to close it on the pulley teeth. Might take some of the load off the engine/tranny guts while youre bustin the nut loose. Maybe a hunk O wood, tween engine & vise grips,, |
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Title: Re: Drive belt snapped ! Post by sluggo on 12/21/10 at 17:41:21 7D51486F7D5F425C5549300 wrote:
i havent heard from berts forum since he got married. |
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Title: Re: Drive belt snapped ! Post by photojoe on 12/21/10 at 18:37:32 First time I've heard that about a Savage, but hey, they don't last forever. And that price you paid, 325.80, holy shite! Did you get soup and salad with that? Sorry to hear it though really. |
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Title: Re: Drive belt snapped ! Post by sluggo on 12/21/10 at 18:38:36 3D2522392227224D0 wrote:
did ya get a kiss, everybody should get kissed when their getting screwed 8-) |
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Title: Re: Drive belt snapped ! Post by MaxMayhem on 12/21/10 at 18:40:40 Can any1 quickly give me the torque setting for the 32mm nut on the front drive belt pully? I have the manual at home, but I am at work and cannot d/l the one on Megauploads. Got mates coming over to my work in 1 hour. Hope someone reads this and can help soon. |
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Title: Re: Drive belt snapped ! Post by verslagen1 on 12/21/10 at 20:28:10 ITEM N-m | ft-lb Rear axle nut 55.0 88.0 | 40.5 64.9 Engine drive pulley nut 100.0 130.0 | 73.7 95.8 |
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Title: Re: Drive belt snapped ! Post by MaxMayhem on 12/21/10 at 20:41:35 Thanks for that verslagen1. We are trying to break the nut free, but the pulley just keeps turning, even though in gear. I guess we need to somehow tighten the belt more, but can't see how. Also is it left to loosen, right to tighten? |
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Title: Re: Drive belt snapped ! Post by verslagen1 on 12/21/10 at 20:47:05 I think you torque the nut to make the bike go forward. |
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Title: Re: Drive belt snapped ! Post by justin_o_guy2 on 12/21/10 at 21:33:27 33203736292422202B74450 wrote:
If so, then its left hand thread where a r hand otta be. I say its r hand thread. Someone otta look in a book. |
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Title: Re: Drive belt snapped ! Post by MaxMayhem on 12/21/10 at 21:53:30 Thanks for all the help guys. I still need the answer but I am almost out of time. We having xmas work do, while I'm doing this in the back shed. We have flattened the locking tab on the washer, and tried to do undo it left & right but it's not breaking and the pulley just keeps turning no matter what we try. |
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Title: Re: Drive belt snapped ! Post by justin_o_guy2 on 12/21/10 at 22:14:25 163A23163A22333E365B0 wrote:
Did you run the old belt onto the pulley & clamp it w/ vise grips & then let it swing up onto the engine? That otta hold it. Mitte use a block O wood between engine & vise grips |
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Title: Re: Drive belt snapped ! Post by MaxMayhem on 12/21/10 at 22:31:15 Yip did that justin, but belt just slipped as it turned. We have to go home now, they locking the site up. Can't even start the darn job, cause of this one darn nut. |
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Title: Re: Drive belt snapped ! Post by Bubba on 12/22/10 at 07:20:50 I may be wrong here but I pulled the belt of my bike before I yanked the engine. If I recall, I removed the stator cover and then angled the belt out of there. Hope that helps... P.S. That was with the rear wheel already off, bike in neutral and I did not have to remove the pulley. |
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Title: Re: Drive belt snapped ! Post by DBC on 12/22/10 at 11:37:52 I don't know if you have Impact Driver at your disposal, but thats what I used. Just put it in first gear and the nut comes right off. I just did mine yesterday as I did my teardown for my cafe project. I made the mistake of removing the rear wheel before removing the drive pulley so that was really the quickest way for me to do it (rather than putting the swing arm an wheel back on just to take off a pulley). |
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Title: Re: Drive belt snapped ! Post by Boofer on 12/23/10 at 06:48:46 Clymers says to put transmission in NEUTRAL and have someone hold back brake on to take nut off. I realize you can't do this, but a little engineering and patience should provide a way to make belt hold pulley while loosening nut. Clymers states on page 127 to make sure the belt is properly meshed with the drive and driven pulleys before re installation or belt teeth CAN BE STRIPPED. Page 148 shows "Engine drive pulley nut" should be torqued to 100-130 Nm or 73-94 ft lb. Page 290 also shows installation procedure. Left hand threads are not mentioned. Also, start to bend washer tab slightly before installing to give a headstart on tapping it over nut flat. Someone mentioned impact wrench. I wonder if Harbor Freight's cheap electric is any good. A little PB Blaster and impact can move mountains, but I don't have air and wonder if electric is okay for those once a year jobs? Anyone have one? Boofer |
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Title: Re: Drive belt snapped ! Post by Boofer on 12/23/10 at 06:57:38 Verslagen, Didn't notice you had posted torque values. And others. I've never done this. Just stating what manual says for information. Not trying to sound like I know what I'm doing. But my uncle taught me when I was a young'n you can do a lot with a block of wood and a hammer. ;) |
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Title: Re: Drive belt snapped ! Post by Serowbot on 12/23/10 at 07:34:49 It's a standard thread, (lefty loosey)... and I had to use an electric impact wrench to get it off... I did it with the tranny in neutral to avoid any internal damage... try to wedge something into the pulley teeth to give you something to crank against... my belt was intact, so I had a friend sit on the bike and hold the brake pedal down... ... and beg, borrow, or steal (or rent) a powered impact wrench... Best luck... ... once again, to be clear... it's CCW to loosen.... standard thread direction... ;)... |
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Title: Re: Drive belt snapped ! Post by MaxMayhem on 12/23/10 at 11:26:09 Ok. I got the job done yesterday. Here is how it went and quite easy too. Remove front pulley cover. Undo bottom bolt on left hand suspension and lift suspension out of the way. Remove belt guard. Remove broken belt if it did not fall off when it broke. Use this time to clean any build up of scum & dirt etc from around pulleys etc. Put engine into neutral (This allows the pulley to turn freely for next step). Use old belt around front pulley and clamp together with locking-pliers. turn pulley until locking-pliers butt up against the engine cover. Use a flat screwdriver or similar and hammer to tap flat the washer behind the 32mm nut on the front pulley as this stops the nut spinning off in a worst case scenario. (Why Suzuki put a nut on here that loosens the same direction as it drives I don't know) Once washer has been tapped down flat, put bike in gear, put front wheel against a wall, then use a ratchet-gun with a 32mm socket and turn LEFT to loosen. Once nut is off the washer will come off, followed by the pulley. Fit new belt to front pulley and put pulley back on. Note the washer has small notches that match the spindle the pulley goes on to. Important - using screwdriver bend the washer back up. Use ratchet gun to tighten 32mm nut back up (not too tight or you will over torque) Now loosen the rear wheel bolt and slacken off the belt adjusters on either side (The adjusters may not need to be slackened off, but I felt it didn't make the job any harder) Push, kick whatever you want the rear tyre in towards the direction of the handlebars as much as you can. Now loop the new belt over the top of the rear pulley. Once you have the belt teeth in the top of the rear pulley as snug as possible, straddle the bike, put the bike in neutral and slowly reverse the bike. The belt will fit itself as you reverse. Once belt is on give it a look over to make sure it is on correctly, then re-align the belt with the belt adjusters on either side of the bike. Retighten up the rear wheel bolt & front pulley nut to the torque settings Verslagen1 mentioned earlier. Put covers back on, (Also as I found out the hard way, when tightening the 3 bolts on the front pulley cover, do so very gently. I went only a little bit to far on the short top bolt and stripped the inner thread.) Then the rear left suspension. Tip here, get someone to lift the weight from the rear end when you refit the suspension as the bolt tends not to line up with the weight pushing down towards the wheel. Check everything is back on, tight and no spares left over and your good to go. |
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Title: Re: Drive belt snapped ! Post by sluggo on 12/23/10 at 13:23:14 what? no leftover parts, then the job is done wrong, i always have leftover parts. ;D |
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Title: Re: Drive belt snapped ! Post by mick on 12/23/10 at 13:32:33 just one thing max,in the book they reccomend using a new washer after the tab has been bent and rebent. Oh well next time huh ? |
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Title: Re: Drive belt snapped ! Post by justin_o_guy2 on 12/23/10 at 14:18:07 Check everything is back on, tight and no spares left over and your good to go. Next week, when you find a nut or bolt layin around, youre gonna scratch yer head & ask yerself Where did that GO?? Congrats, ya DId IT! Sorry it cost so much. Next time you need something, ask around before spending Big $$$.. someone may have something you can have for cheap, or freight. |
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Title: Re: Drive belt snapped ! Post by sluggo on 12/23/10 at 14:23:06 524D4B4C51566757675F4D410A380 wrote:
i second that motion. |
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Title: Re: Drive belt snapped ! Post by MaxMayhem on 12/23/10 at 16:56:07 I would have asked if time wasn't a major factor this time around. My ability to get to work atm with jobs scarce around here, meant I had zero options but to get the part, get it now, and get it fixed. $tealership may be expensive but they had it less than 24hrs after ordering it, and as I live in the country about 30 mins ride from where I work in the city, I could not afford to wait. And as most of you are in the states and I am in New Zealand, the time would have been too long. If I notice things that are beginning to wear out etc I will post up large here to see what others can help with, but let's face it, it's usually the unforseen things that tend to happen at just the wrong time. mick: I saw no reason than the manual covering it's ass legally to replace the washer after each use. You should be able to bend the same spot at least twice and then still use opposite side a couple times after that. For all it's flexability that washer is pretty strong, though I would not rebend the same side more than twice, but would order a new one If I planned to do this again just to be on the safe side. Boofer: I used a 24v battery Impact Wrench that a mechanic around the corner from my work let me borrow for nothing as long as I didn't take too long. Worked a treat. So today I bought some oil and oil filter to do oil change over xmas break as bike hasn't had one since I got it and is at 27799km (I purchased at 15000km), and mid Jan I am doing the Verslagen1 cam-chain tensioner mod. I myself will not be doing the actual mod, but a mate who I have shown the before and after pictures, has told me it'll only take about 1/2 hour for him to do for $0.00 (I reckon add a couple hours more for fidggeting around) once I have removed the tensioner etc and given to him. (He is an automotive engineer and his boss let's him use the work gear for personal stuff as long as he doesn't have anyone hanging around the workshop.) Then I will do another oil change once that is done since I will have to drain most the oil anyway, just to get any particulates that might get in once tensioner engine covers are off, just to be safe |
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Title: Re: Drive belt snapped ! Post by sluggo on 12/23/10 at 17:56:00 a filter, what the heck is that. :D |
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Title: Re: Drive belt snapped ! Post by Serowbot on 12/23/10 at 19:55:12 My pulley has been coming loose, again and again. It started with a rattly chirp, and I traced it to a just barely loose pulley,... tightened it up and it went away... ... then it came back,... ... and again, and again... I've cranked that sucker past 130 ft.lbs with red locktight... and it still comes loose... My bike is a torque monster... and that nut is the proof... It's chirpin' again,.... this time I'm goin' for a new washer, red locktight, and driving it on with an impact wrench... ... that don't hold it,.. call Guinness... :-?... |
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Title: Re: Drive belt snapped ! Post by verslagen1 on 12/23/10 at 20:02:28 Check to make sure the splines aren't loose. Then I'd assemble with some gap filler in the splines. |
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Title: Re: Drive belt snapped ! Post by ralfyguy on 12/23/10 at 20:04:47 3224332E36232E35410 wrote:
Thats just plain NUTS! ;D |
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Title: Re: Drive belt snapped ! Post by ralfyguy on 12/23/10 at 20:09:20 Seriously now, here's a trick: Take a file and file a few flat spots on the shaft threads. Doesn't have to be much, just a hit or two, about three of them and 120 degrees apart. Don't file it all off, just about half way down will do it. Then put Loctite on it, not too skimpy. The Loctite will gather between the flat spots and the nut and when hardened act as a wedge. The filing won't hurt the function of the thread at all and is completely reusable if the pulley has to be ever removed again. |
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Title: Re: Drive belt snapped ! Post by justin_o_guy2 on 12/24/10 at 00:23:19 7563746971646972060 wrote:
If that was my hassle to solve Id look real close at how the pulley fits on the shaft. If its able to rotate on the shaft, that may be where the hassle starts. Is it keyed? Id hafta look at a book,, |
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