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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Pulley /cgi-bin/YaBB.pl?num=1538164013 Message started by Drifter.. on 09/28/18 at 12:46:53 |
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Title: Pulley Post by Drifter.. on 09/28/18 at 12:46:53 This question is for Dave or anyone who knows the answer. How much on each side of Kawasaki pulley needs to be machined off? Thanks in advance. |
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Title: Re: Pulley Post by badwolf on 09/28/18 at 14:28:29 The sides of the pulley near the shaft need to be the same as the stock pulley. Just measure and copy. The kaw pulley is hardened and you will need to take small cuts and sharpen your tool bit often, or use a grinder as it turns on the lathe, and finish with a pass with a cutting bit to true it up. You can cut the dia. of both side flanges down to the height of the belt. Easiest to do on a lathe, then round the tops off with a file. While it is chucked up, smooth off the peening on the sides A LITTLE, don't get carried away on the sides or the flanges can loosen up or fall off. (THAT WOULD BE BAD) You will still need to grind the case a small amount with a hand grinder, fit the cut-down pulley by hand and you will see where. Don't put the belt on or tighten it down till you are sure it clears everything. All and all pretty easy,IF, you have access to a lathe. |
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Title: Re: Pulley Post by Dave on 09/28/18 at 19:13:14 2A283B253B392128203B490 wrote:
Yeah....a lathe - and about 3-4 hours of time (for cutting on the pulley and sharpening bits repeatedly)! ;) |
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Title: Re: Pulley Post by badwolf on 09/28/18 at 19:37:25 Dave, The last one I did took about a hour. The grinder don't care if the stock is hard or soft, just makes different color sparks. Use the grinder to take off 90-95%, then just clean it to true with a cutting bit. Saves a lot of time. |
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Title: Re: Pulley Post by Drifter.. on 09/29/18 at 05:55:15 Thank you! Another question, I have an oil leak coming from the bottom frame/foot peg bolt on the left side and yes i am sure its coming from there not the oil drain bolt any ideas? I tightened the bolt it still leaks but less than before. My old savage did not do this? My old Nortons and Triumphs did not leak.... they marked their territory i sure did not expect a 2012 S40 to do the same thing. |
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Title: Re: Pulley Post by verslagen1 on 09/29/18 at 08:04:39 all leaks will find their way to the lowest part of the bike, which is... left side peg. sometimes the oil seeps into the thru bolt holes in the case. retorque them and you're good to go. |
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Title: Re: Pulley Post by Dave on 09/29/18 at 17:12:40 Yep....what Verslagen says. When the front footpeg bolts get loose.....the engine case can leak as they are "through bolts" and they go all the way across the bike. You need a wrench on both sides when you tighten them. |
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Title: Re: Pulley Post by Drifter.. on 09/30/18 at 10:34:35 So if i remove the bolt altogether it turns into a drain plug? I guess you are never to old to learn something new! |
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Title: Re: Pulley Post by verslagen1 on 09/30/18 at 11:32:36 4E78636C7E6F7824240A0 wrote:
No, but oil seeps into there and will leak when loose. If you want an alternate drain plug, remove the timing port and tip the bike over. But, I wouldn't want to do that a lot, metal filings and permanent magnets. |
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Title: Re: Pulley Post by Dave on 09/30/18 at 13:25:53 76405B544657401C1C320 wrote:
The bolt hole does not go into the crankcase - but when the bolt is loosened it allows oil to seep out the mating surface of the two crank halves....and for some reason it likes to seep into the hole the bolt goes through. So....it will work as a drain plug if you have 10-12 years to wait! |
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