I think he's got it all figured out fairly well,  Justin, as his choices are:

1) totally shafted and sheared off short,

2) totally spineless

3)  or if he is jest plain lucky he's jest got him a wallowed out hole in the center of his driven pulley.


   


Me, I have faith in Serenity and him having found option #4 -- the infamous something new and unexpected .....

Oldfeller--FSO wrote on 06/07/11 at 21:01:54:

I do my best to keep you old-timer mechanics thinking and pondering.  It's a good prevention for Alzheimer's!  

Exactly the same symptoms occurred with my '96 Savage at 14K miles. The cause was that the nut securing the drive pulley to the transmission output shaft had become loose despite the lock washer being bent against one of the nut's flats. The free play of the cogged pulley against the splined shaft caused the cogs on the pulley to strip. I regard this as a design flaw, but at least the engineers specified a harder grade for the shaft than the pulley, so most of the damage was to the pulley.

When I replaced the pulley with a new one I applied Loctite 660 Retaining Compound to splines. This Loctite is specifically designed for shaft repairs. I torqued the nut to specs and bent the edge of a new lock washer against one of the nut's flats. That was 3K miles ago and all is holding.

I removed the nut with an electric impact wrench and put it on with a manual beam bar torque wrench.  To gain resistance put the bike in gear (I used 2nd), put a socket and breaker bar on the pulley nut, and determine which way the bike wants to go when you rotate the nut. Then block the rear wheel with a 4"x4" wooden block to prevent that motion.

Step 1, get the washer flattened out good. The nut shouldnt actually be torqued any more, since the pulley i spinning on the shaft freely, so, in 1st gear, the impact otta just spin it off,, seems to me you should be able to spin it off with a ratchet easy enough, but, ya never know till ya get in there.


& as for me bein some kinda long distance diagnostician,, I read others posts & they were leadin ya there, just in a different way,, Im no guru here,, plenty others are. We're all just glad the dang shaft isnt busted..
I wouldnt worry too much about the shaft being hurt, the pulley is much softer & even if the shaft is somewhat damaged, a new pulley & some good epoxy & you wont be in that engine..

I read OF's post,, & I see another option to popping a case. Might be a bad idea, IDK, but Id sure consider backing off the valve adjusters & setting the piston at 1/2 way down the stroke, to put the crank at 90* & filling the cylinder with oil.

I just hope his shaft is ok...  

verslagen1 wrote on 06/09/11 at 07:07:07:

It's the shaft that has to be held, not the pulley. The pulley splines are worn down and the shaft spins separate from the pulley now.  I'm gonna try an air impact wrench on it either this evening or tomorrow.