SuzukiSavage.com - front pulley

greyhead51 Junior Member Offline i love u charlotte Posts: 57 munford,tn Gender:	front pulley 03/07/08 at 18:15:07 has anyone ever had a problem getting the front pulley off? for some reason mine is stuck. thanks and God bless...greyhead51
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Kropatchek Serious Thumper Offline Why more than 1 cylinder? Posts: 1457 Alphen a/d Rijn Netherlands Gender:	Re: front pulley Reply #1 - 03/08/08 at 08:20:21 greyhead51 wrote on 03/07/08 at 18:15:07: has anyone ever had a problem getting the front pulley off? for some reason mine is stuck. thanks and God bless...greyhead51 It is not stuck, just f....g tight, 130Nm. An impact driver will work the best.
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greyhead51 Junior Member Offline i love u charlotte Posts: 57 munford,tn Gender:	Re: front pulley Reply #2 - 03/08/08 at 09:27:18 it's not the nut, i can get it off, it's the pulley itself, won't budge. guess i'm ok as long as the pulley doesn't go bad. what then?? thanks and God blessgreyhead51
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T Mack 1 - FSO

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Re: front pulley
Reply #3 - 03/08/08 at 12:45:54

Ok...... take a look at the shape of the splines (at least what you can see).

If you see that the sprocket isn't nicely matched up to the shaft, then worry about taking it off, in other words, with gaps that look like there could be movement.

If they are nicely matched up then leave it on.

MAKE SURE you torque that nut back on to spec!!!!!! If you don't have the tools to do that, get it as tight as you can, then drive to a shop that has the tools.

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Engineers design things, Technicians make them work.
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30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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greyhead51 Junior Member Offline i love u charlotte Posts: 57 munford,tn Gender:	Re: front pulley Reply #4 - 03/08/08 at 15:25:07 what i'm asking is, does anyone know how to remove a pulley that won't budge (yes the nut will come off) greyhead51
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: front pulley Reply #5 - 03/08/08 at 16:01:46 Clymer says to carefully remove drive pulley, but not how. Might I suggest a gear puller?
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T Mack 1 - FSO Serious Thumper Alliance Member Offline sold 2001 LS650 for a 1986 XLH1100 Posts: 2919 Emmaus,Pa Gender:	Re: front pulley Reply #6 - 03/08/08 at 17:24:02 Have a dumb question for you, sorry in advance. Is the belt loose? See, told you it was a dumb question.....
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barry68v10

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Re: front pulley
Reply #7 - 03/09/08 at 05:14:07

T Mack 1 - FSO wrote on 03/08/08 at 17:24:02:

Have a dumb question for you, sorry in advance.

Is the belt loose?

See, told you it was a dumb question.....

There are no dumb questions, only dumb people. Grin

That was a good point! If the belt is loose and the front pulley still won't come off, whack it a couple times top and bottom with a rubber mallet. It should just slide off.

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T Mack 1 - FSO

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sold 2001 LS650 for
a 1986 XLH1100

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Emmaus,Pa
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Re: front pulley
Reply #8 - 03/09/08 at 07:34:01

barry68v10 wrote on 03/09/08 at 05:14:07:

T Mack 1 - FSO wrote on 03/08/08 at 17:24:02:

Have a dumb question for you, sorry in advance.

Is the belt loose?

See, told you it was a dumb question.....

There are no dumb questions, only dumb people. Grin

That was a good point! If the belt is loose and the front pulley still won't come off, whack it a couple times top and bottom with a rubber mallet. It should just slide off.

A little WD-40 before you whack it could help too.

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Engineers design things, Technicians make them work.
---
30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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rigidchop Serious Thumper Offline don't feed the drama llama Posts: 1105 ravenswood wv Gender:	Re: front pulley Reply #9 - 03/09/08 at 13:06:55 dead blow hammers work well. and i'm more fond of pb blaster myself.
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justin_o_guy2

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What happened?

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Re: front pulley
Reply #10 - 03/10/08 at 06:16:02

Since it is the output shaft I would expect it to be stout & well supported inside the tranny, but I dont know if the shaft is able to handle impact without damaging a seal or bushing/bearing whatever is inside. A slide hammer to pull it off, or a gear type puller, so as to avoid any impacts & yanking around on the putput shaft may be a better answer. I dont know. Others here know what IS in there & how , Uhh, Vigorous? you can safely get, pulling that pulley.

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KwakNut Senior Member Offline SuzukiSavage.com Rocks! Posts: 332 Sheffield, England, mostly. Gender:	Re: front pulley Reply #11 - 03/10/08 at 08:32:37 When I came to take the front pulley off mine I found the nut was so loose I could undo it by hand - just glad I chose to strip the bike straight away rather than ride it for a while. The previous owner also almost ran it dry of oil, so a loose nut was no surprise. Some chimps just shouldn't be let anywhere near tools.!
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Rogue_Cheddar

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Re: front pulley
Reply #12 - 03/11/08 at 09:45:41

greyhead51 wrote on 03/08/08 at 15:25:07:

what i'm asking is, does anyone know how to remove a pulley that won't budge (yes the nut will come off)

greyhead51 Huh

Some auto parts stores allow you to rent tools for free (just require a deposit that you get back when you return the tool). I had to rent a pulley puller for the Savage last season. Just make sure you get a puller thats not too large and that you can convert from three prong hooks to two. You can't get three hooks around that front pulley, only two, there's not enough room. You also may have to take the puller apart and reassemble to use the narrow hook ends. Most pullers come with wide and narrow hook ends. Just gotta flip them around.

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