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Message started by Jahoo on 02/22/11 at 17:35:13

Title: Replacing main and counter shaft?
Post by Jahoo on 02/22/11 at 17:35:13

Brought my bike into the shop and they told me that the Main or counter shaft is probably broken. Anyone ever replaced one of these and know exactly what parts im going to need to get this job done. Any suggestions or help would be very appreciated. Thanks guys.

Title: Re: Replacing main and counter shaft?
Post by verslagen1 on 02/22/11 at 17:45:24

I betcha they're wrong.
we've only seen one counter balancer go and never seen a crank go.

you never told us what year or how many miles?

pre 90 most likely starter
any year likely to be cam chain.

Title: Re: Replacing main and counter shaft?
Post by justin_o_guy2 on 02/22/11 at 18:30:02

Look in a mirror. Have your eyes changed color? Are they a smokey gray, with a hint of blue? If so, someone is pumpin smoke up yerazz...

Title: Re: Replacing main and counter shaft?
Post by verslagen1 on 02/22/11 at 19:08:09

At any rate, you're better off gettin' a used engine then getting them to fix it. cheaper to buy a brand new bike.

Have fun, take it apart your self.

Title: Re: Replacing main and counter shaft?
Post by justin_o_guy2 on 02/22/11 at 21:04:12

Have fun, take it apart your self.

AB soooo Tivelee & POSI lutelee.. !

Title: Re: Replacing main and counter shaft?
Post by MotoBuddha on 02/23/11 at 08:17:54

"Countershaft" and "counterbalancer shaft" are two different things. The countershaft is also known as the transmission output shaft --- the thing the sprocket/pulley mounts to.

Title: Re: Replacing main and counter shaft?
Post by greenmonster on 02/23/11 at 10:30:56

What is your bike doing that makes them think you have busted shafts?

Title: Re: Replacing main and counter shaft?
Post by Max_Morley on 02/23/11 at 11:18:22

?? stripped front pulley?? I've been running a Savage since 98 and used the German board before this one and never heard of this failure. Not that is isn't possible but I'd get a 2nd opinion before doing any more. The bike is simple enough and there is lots of help on here, it should be a DIY project. Max

Title: Re: Replacing main and counter shaft?
Post by MotoBuddha on 02/23/11 at 12:06:17

In a thread I can't find right now, a couple of people talked about and showed photos of their stripped front pulleys. One had just a sliver of splines left. But it's the pulley that wears down, not the output shaft/countershaft. The pulley is aluminum and therefore softer than the shaft.

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 02/23/11 at 14:28:24

well the bike is a 97 with 13k on it. I can get the bike started but it wount go. When i roll it forward it makes a clicking sound, and it shifts into every gear it just wount go. Tommorrow when i get off school i'll check it out and see what else I can find.

Title: Re: Replacing main and counter shaft?
Post by MotoBuddha on 02/23/11 at 14:36:21

Maybe check this: take off the front sprocket cover, hold the big nut still and see if the pulley turns. If so, the pulley is shot. I know where you can get a used one for very cheap. ::)

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 02/23/11 at 15:03:37

I'll check it out tomorrow. Anyone have any other suggestions?

Title: Re: Replacing main and counter shaft?
Post by verslagen1 on 02/23/11 at 17:15:59

Yep, I'd say it's the drive pulley.

Another case of they 'saw you coming'

But he didn't know you had back up.

Title: Re: Replacing main and counter shaft?
Post by Reelthing on 02/23/11 at 18:40:39

this is what happens if the nut isn't tight -

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1130022642/8#8

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 02/25/11 at 11:29:48

Ok so my engine is still on the bike and everything is still connected so the bikes back tire is still on the ground.now I removed the front sprocket cover and couldn't move the pulley while holding the nut, now when i did move the nut it made a sound like clicking as it turned. Should i take off the belt then try to move the pulley?

Title: Re: Replacing main and counter shaft?
Post by verslagen1 on 02/25/11 at 11:54:13

With the tire on the ground and belt installed, you holding the nut (I suppose)... ground preventing tire movement, belt movement and pulley movement. Not being able to move anything = no noise.

With the tire on the ground and belt installed, ground preventing tire movement, belt movement and pulley movement. You now move the nut and get noise. So, problem is between the nut and pulley, i.e., bad splines.

Remove nut, check splines.

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 02/25/11 at 12:27:53

So when bike is in nuetral i can move the nut but when i put it into gear i can't.

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 02/25/11 at 12:28:59

Or i should say i can take the nut off now tha it's in gear insted of it just spinning and making that clicking noise.

Title: Re: Replacing main and counter shaft?
Post by MotoBuddha on 02/25/11 at 12:36:04

644F4641412E0 wrote:

I think it's probably rather hard to turn the nut and the shaft it's attached to, because you would also be trying to turn the gears in the transmission. If the pulley splines are worn it would be easier to hold the nut still and try to turn the pulley. That means the belt would need to be able to move. I think there are two ways to accomplish that. The easiest is to hold onto the nut while someone rolls the bike back and forth a little. The other would be to jack up the rear wheel, loosen the axle and adjusters, then slide the wheel forward enough so the belt is loose on the pulley. You would be able to wiggle the pulley forward and back -- if the splines are the problem.

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 02/25/11 at 13:08:07

pulled pulley off, and the teeth that line up to the shaft are worn down, i am gonna snap some photos and upload them but that's gonna be part number one to replace. Now how do i get this shaft out to check the splines and everything else? do i have to take the engiune off of the frame like the clymer says?

Title: Re: Replacing main and counter shaft?
Post by verslagen1 on 02/25/11 at 13:27:24

To take the shaft out, I think you'll have to split the case.
Most often it's just the pulley. I'd leave the shaft where it be.

Title: Re: Replacing main and counter shaft?
Post by MotoBuddha on 02/25/11 at 14:46:51

Yeah, if the pulley is bad, then there's not much chance the output shaft is a problem. Like I wrote before, the pulley is aluminum and the shaft is steel, so the pulley will go bad and get totally stripped before anything happens to the shaft.

Title: Re: Replacing main and counter shaft?
Post by Serowbot on 02/25/11 at 15:03:59

I'm having the same problem with that nut...
It keeps coming just a fraction loose, and making a noise that sounds like a loose chain, on decel...
I've tightened it up with a 250lb impact driver, and it still loosens.
Gonna' buy a new toothed washer and crank it down again,... maybe with lock-tite...
Shows no wear on the pulley or the shaft,... I suspect wear on the teeth of the washer....
Whatabooger!... :-?...

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 02/25/11 at 19:22:43

do you think i should replace the pulley first then try and see what happens before i go all crazy and pull the engine apart. and my next question who has a good pulley i can buy?

Title: Re: Replacing main and counter shaft?
Post by MotoBuddha on 02/25/11 at 19:38:25

A basic rule of repairs when you're not sure exactly what's the problem: try the simple, less expensive things first.

Opening the crankcase should be the last thing you try.

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 02/28/11 at 12:01:34

ok now that the pulley is off when i move the shaft no clicking....i'm heading down to get the new pulley i just bought and since it's a bike shop i'm hoping they might have a gasket cutter. Now to just find a carb cleaning thread and i'll be set.

Title: Re: Replacing main and counter shaft?
Post by verslagen1 on 02/28/11 at 20:11:32

seek and yee shall find...

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1191899985

Title: Re: Replacing main and counter shaft?
Post by Jahoo on 03/15/11 at 14:33:28

Guys front pulley is on. Bike is now running and...(drum roll please)...Driving. Yes My savage is mobile. Thank you all for all the help.