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Message started by Rylee on 03/09/15 at 21:38:06

Title: Installing ryca thumb decomp lever
Post by Rylee on 03/09/15 at 21:38:06

So I bought the bike with the decomp system removed but without any type of manual decomp setup. Grabbed the thumb lever off the RYCA website and was ready to install it. The photo shows what's left from PO removing the original setup. I tried to watch the tutorials on the RYCA YouTube but it doesn't show the actual installation process. My problem is as I turn the bolt with the wrench it just actuates the decomp and doesn't seem as if there's a stop. I'm scared to turn it to far in the event I may damage something. Is there some sort of way to hold the valve closed to break the nut loose that I'm missing. Or will it actually stop turning forward and allow me to break the nut loose.

Title: Re: Installing ryca thumb decomp lever
Post by verslagen1 on 03/09/15 at 22:30:01

dave's your guy, he's probably done it.

I'd guess that you put a crescent wrench on the shaft inside the valve inspection cover.

Title: Re: Installing ryca thumb decomp lever
Post by Dave on 03/10/15 at 03:10:20

Hey....Glad to know I might be good at something!

You can turn the shaft.....I don't believe there is a stop of any kind and it will just keep on turning. If you can turn the shaft without resistance - that means the exhaust valves are open.....you could rotate the crankshaft and get the valves closed and that may offer enough resistance to allow you to take the nut off.

As a last resort - find the correct sized very skinny wrench to put on the flats if the shaft where the lever is supposed to go. If you have to make one.....used the RYCA lever as a pattern for the size of the flats.

Title: Re: Installing ryca thumb decomp lever
Post by justin_o_guy2 on 03/10/15 at 03:23:05

Maybe summa them needle nose vise grip..

Title: Re: Installing ryca thumb decomp lever
Post by Gary_in_NJ on 03/10/15 at 05:11:11

I put a C-clamp on the arm. This held it in place while I removed the arm.

Title: Re: Installing ryca thumb decomp lever
Post by Rylee on 03/10/15 at 09:10:14

Thanks for allthe replies. There really doesn't seem like enough exslosed area to grab the shaft itself. I tried using the thumb lever to grab it and break the nut free but it just slipped off. I'm gonna open the inspection plate and see if I can pin it in there.

Title: Re: Installing ryca thumb decomp lever
Post by Gary_in_NJ on 03/10/15 at 09:50:01

I found that a 1-1/2" C-clamp from the top side of the lever to the upper surface area/cavity where the spark plug resides held the lever in the down position. I just did this two weeks ago so I know it works.

Title: Re: Installing ryca thumb decomp lever
Post by Dave on 03/10/15 at 10:00:47

6B61656F646D69603E383C0C0 wrote:

Gary.....He does not have a lever on the shaft. The previous owner took the lever off, and then tightened the nut on the shaft.....without any lever.

There really isn't anything inside to grab either.......it is a round shaft with a bit of a ramp ground away.

I would suggest getting the engine where the valve springs are pushing down - then using an impact to jar the nut loose and hopefully not rotate the decompression shaft in the process.

And....if you take out the retaining bolt....the one that is at a 45 degree angle - can you remove the shaft completely and then stick it in a soft vice to hold it while you take the nut off? It looks like the shaft can come out.........?

http://www.hondaofflorence.com/fiche_section_detail.asp?section=432118&category=Motorcycles&make=SUZUKI&year=2005&fveh=10118

Title: Re: Installing ryca thumb decomp lever
Post by justin_o_guy2 on 03/10/15 at 10:29:35

Penetrating oil,heat nut with soldering gun, ice on shaft, quick ,,wrench on and slap it..good luck

Use Dave's setup,,

Title: Re: Installing ryca thumb decomp lever
Post by Gary_in_NJ on 03/10/15 at 11:21:13

704B4651404C57514A424F50230 wrote:

He does not have a lever on the shaft. The previous owner took the lever off, and then tightened the nut on the shaft.....without any lever.

I had to turn my laptop sideways to understand the photo. Now I see the problem.

Title: Re: Installing ryca thumb decomp lever
Post by Dave on 03/10/15 at 11:46:41

404A4E444F46424B151317270 wrote:

[quote author=704B4651404C57514A424F50230 link=1425962290/0#7 date=1426006847]He does not have a lever on the shaft. The previous owner took the lever off, and then tightened the nut on the shaft.....without any lever.

I had to turn my laptop sideways to understand the photo. Now I see the problem. [/quote]

I think that if the retaining bolt is taken out...the shaft will slide right out...and then he can get a grip on it and have the nut off easily.