SuzukiSavage.com - HELP ! Removing Front DRIVE PULLEY Nut

T Mack 1 - FSO Serious Thumper Alliance Member Offline sold 2001 LS650 for a 1986 XLH1100 Posts: 2919 Emmaus,Pa Gender:	Re: HELP ! Removing Front DRIVE PULLEY Nut Reply #15 - 11/06/07 at 02:53:12 Suggest buying, renting or borrowing an impact wrench. A breaker bar with pipe extension puts a bunch of torque on it, enough to wreck stuff. Remember to bend down the locking washer.
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Savage_Greg

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Re: HELP ! Removing Front DRIVE PULLEY Nut
Reply #16 - 11/06/07 at 05:01:46

Lefty loosie on the nut.

Can't get someone to hold the brake while your turn the nut?

You could also try to put a bar or pipe through the rear pulley and block it against the swingarm.

Did someone say that they were trying to turn it with a torque wrench? I've always heard that you shouldn't break bolts loose with a torque wrench.

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slavy

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Re: HELP ! Removing Front DRIVE PULLEY Nut
Reply #17 - 11/06/07 at 12:02:15

There are couple of tricks, but the first thing I'd do is :
I'd pull the pulley cover and I'd ride the bike to the closest auto or mc repair place , and I'd ask ANY mechanic to do it for me. After that without hesitation, I'd give him $5 for the 1 minute job. I'd screw back the nut without torqueing it too much , and I'd go back home and keep doing what I wanted to do.
If not- just pull the spark plug out and take a long 1/4'' cotton rope. Put the piston in bottom dead center before the compression stroke, and stuff the space above the piston with a lot of rope. After that use the socket with a long bracker bar. The piston will keep going up untill it stops in the compressed cotton. Once You are done, just back the piston, and pull the rope out.

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Savage_Greg

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Re: HELP ! Removing Front DRIVE PULLEY Nut
Reply #18 - 11/06/07 at 12:20:00

slavy wrote on 12/31/69 at 16:00:11:

There are couple of tricks, but the first thing I'd do is :
I'd pull the pulley cover and I'd ride the bike to the closest auto or mc repair place , and I'd ask ANY mechanic to do it for me. After that without hesitation, I'd give him $5 for the 1 minute job. I'd screw back the nut without torqueing it too much , and I'd go back home and keep doing what I wanted to do.
If not- just pull the spark plug out and take a long 1/4'' cotton rope. Put the piston in bottom dead center before the compression stroke, and stuff the space above the piston with a lot of rope. After that use the socket with a long bracker bar. The piston will keep going up untill it stops in the compressed cotton. Once You are done, just back the piston, and pull the rope out.

Done that before too...but of course, now we're talking about removing the seat and tank in order to remove the pulley...

Or you could remove the clutch cover and jam the primary gears with a piece of aluminum...

Or you could go buy an air compressor and an impact wrench and socket...

So many options... Tongue

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Hutch Serious Thumper Offline till death do us part Posts: 1035 Birch Run, MI. U.S.A. Gender:	Re: HELP ! Removing Front DRIVE PULLEY Nut Reply #19 - 11/06/07 at 19:26:36 I had the same problem with mine. I agree with Slavy, take it to a tire shop. That is what I did, and it took several tries to break it loose with the impact. Mine had a ton of locktite from the factory. Hutch
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strangeling

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Re: HELP ! Removing Front DRIVE PULLEY Nut
Reply #20 - 11/06/07 at 20:11:24

Thanks guys,

I ended up taking to a performance auto shop a couple of streets down from me and he helped me out getting it undone for free.

Well got everything done now I just have to remove a couple of links from the chain tomorrow and I will test this sucker out. I'll report back on my thoughts tomorrow.

And Hutch thanks for coming up with this idea, other than the pulley nut problem the conversion was cake !

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Hutch Serious Thumper Offline till death do us part Posts: 1035 Birch Run, MI. U.S.A. Gender:	Re: HELP ! Removing Front DRIVE PULLEY Nut Reply #21 - 11/07/07 at 05:31:06 Strangeling, can't wait to see how you like it. You can always dial it in to your preference by playing with ratios. Beats the heck out of living with what the factory gave you. Hutch
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Re: HELP ! Removing Front DRIVE PULLEY Nut
Reply #22 - 11/07/07 at 09:32:56

strangeling wrote on 12/31/69 at 16:00:11:

Thanks guys,

I ended up taking to a performance auto shop a couple of streets down from me and he helped me out getting it undone for free.

Well got everything done now I just have to remove a couple of links from the chain tomorrow and I will test this sucker out. I'll report back on my thoughts tomorrow.

And Hutch thanks for coming up with this idea, other than the pulley nut problem the conversion was cake !

Good job. Hope that you can ride it in several different kinds of areas for a good overall review.

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Bobbing Tom YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 7	Re: HELP ! Removing Front DRIVE PULLEY Nut Reply #23 - 07/28/12 at 19:37:35 What does the manual mean by "flatten out the lock washer" ?
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Re: HELP ! Removing Front DRIVE PULLEY Nut
Reply #24 - 07/31/12 at 03:39:51

Ok have found the answer to my question abve.
Now the problem is the tab had been broken off and messee up previously Sad

I have tried to undo the nut anyway out of frustration, it moves with a bang but seems to be turning the internals as well (I marked the edge of the nut and drive shaft). Anyone got any suggestions for removing the pully with an unhelpfull pulley nut? I think I will have to put her back together and head to the mechanician :'(

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Oldfeller--FSO Serious Thumper ModSquad Offline Hobby is now "concentrated neuropany" Posts: 12672 Fayetteville, NC Gender:	Re: HELP ! Removing Front DRIVE PULLEY Nut Reply #25 - 07/31/12 at 03:51:54 There is a Tech posting on that subject. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1335739552 If you are describing the inner shaft and nut (as a unit) rotating inside the front pulley, you have stripped splines in the pulley. Actually, it is unclear what you are trying to describe --- try again please.
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