SuzukiSavage.com - remove crankcase cover without taking out enigne?

guffikins

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Re: remove crankcase cover without taking out enig
Reply #30 - 08/07/16 at 10:15:37

Thanks all for the help and advice!

Hasn't gone as planned yet, unfortunately.

We had no problems getting the cover off, getting the gasket pulled, putting the new one on and reassembling it (thanks for the washer advice). Unfortunately when we fired it up on the stand, we got a pretty spectacular rattle seemingly in the transmission- only happens with the clutch out and in gear. Everything appears to be in place and moving freely and appropriately (starts fine, no wear in the cover, etc). Is this likely to be a related problem, or have we found a new and exciting problem to fix? The link below is a set of pictures- if there's anything obvious we've screwed up in there, feel free to point it out. Thanks!

http://imgur.com/a/boMYV

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batman

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Re: remove crankcase cover without taking out enig
Reply #31 - 08/07/16 at 19:23:20

GRUFF ,looked at your pic's you did it right!....I have to ask if when the bike went down was it a hard drop? I think you should take the bike for a short ride ,does the noise/vibration occur when running at a constant speed ?or does it occur when shifting or right after shifting? or anything you can tells us (yea ,more info again )

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guffikins

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Re: remove crankcase cover without taking out enig
Reply #32 - 08/08/16 at 07:29:55

batman wrote on 08/07/16 at 19:23:20:

GRUFF ,looked at your pic's you did it right!....I have to ask if when the bike went down was it a hard drop? I think you should take the bike for a short ride ,does the noise/vibration occur when running at a constant speed ?or does it occur when shifting or right after shifting? or anything you can tells us (yea ,more info again )

Glad I got that right- the advice was helpful, that washer definitely fell off.

The drop wasn't a recent one, and the bike has been ridden since so I'm not sure how bad it was in the first place. We haven't had the bike out since, I don't love the vibration and it makes me a little nervous to run it for long while it's banging away. I'll put it all back together and take a video in the next couple days.

As far as info, I can just tell you what we saw:

-Bike starts fine and everything in there seems assembled correctly
-While on the stand, bike bangs away at idle in gear
-When the clutch is pulled or the bike is in N, it sounds fine
-When it's banging away, the front sprocket and belt seem to vibrate a lot

Thanks again!

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youzguyz

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Re: remove crankcase cover without taking out enig
Reply #33 - 08/08/16 at 07:53:42

Check that front sprocket and see if it shifts on the shaft.
That shaft has splines that engage the sprocket, and it has been known for the sprocket to get eaten up by the shaft if the nut isn't tight enough

A thread that might shine light on the subject a bit:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1335739552/0

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Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose.

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batman

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Re: remove crankcase cover without taking out enig
Reply #34 - 08/08/16 at 12:15:56

Gruff,go with youzguyz's advice, that pulley needs to be torqued to 94 ftlbs or it will ruin the shaft (big job ,big money). these bikes vibrate a lot at idle,but the banging ? you might check the the compression release to make sure it isn't set to tight making the little release cam come in contact with the exhaust rocker arm after starting. A video with sound would be helpful.

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verslagen1

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Re: remove crankcase cover without taking out enig
Reply #35 - 08/08/16 at 12:20:05

batman wrote on 08/08/16 at 12:15:56:

Gruff,go with youzguyz's advice, that pulley needs to be torqued to 94 ftlbs or it will ruin the shaft (big job ,big money). these bikes vibrate a lot at idle,but the banging ? you might check the the compression release to make sure it isn't set to tight making the little release cam come in contact with the exhaust rocker arm after starting. A video with sound would be helpful.

75 to 95 ft.lbs.

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guffikins YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 5	Re: remove crankcase cover without taking out enig Reply #36 - 08/14/16 at 15:12:59 Took a bit, but here's the video: https://www.youtube.com/watch?v=UY2re7dO0Hk
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28780 L.A. California Gender:	Re: remove crankcase cover without taking out enig Reply #37 - 08/14/16 at 15:59:43 looks like you gotta pull that pulley.
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: remove crankcase cover without taking out enig Reply #38 - 08/14/16 at 20:00:32 Vercy"s right you need to pull it and hope you don't have damage to the splines on the output shaft ,take another video so we can advice.
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