SuzukiSavage.com - Oil leak on the drive pulley

Ruttly Serious Thumper Offline Thumpers Rule Posts: 5113 Manteca , CA Gender:	Re: Oil leak on the drive pulley Reply #15 - 04/10/23 at 12:13:09 That careful part almost sounds like your speaking of a past screw up ?
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Oil leak on the drive pulley Reply #16 - 04/10/23 at 12:14:18 To tighten the pulley nut, the lockup bar goes under the swingarm. Same cautions apply, heavy/thick web on the pulley must take the load, no wheel spokes touching the lockup bar.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Oil leak on the drive pulley Reply #17 - 04/10/23 at 12:16:38 Make sure the thick web is in contact with the bar (green checkmark), not the thin web (yellow X).
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Oil leak on the drive pulley Reply #18 - 04/10/23 at 12:18:02 A Craftsman breaker bar works OK too.
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Re: Oil leak on the drive pulley
Reply #19 - 04/10/23 at 12:26:42

Let us know how tight your pulley nut is. Loose pulleys are a problem. As mentioned earlier, the splines get damaged when the nut is loose. Try and take some clear pictures and post before you reassemble.

Also, you wanna apply a few drops of high-strength thread locker (red) to the threads before you install the nut. Since you will be goin through all the trouble to remove your pulley, might as well replace the seal and o-ring while you are in there. Make sure that the spacer doesn't have a deep groove worn in it, or any cuts/nicks in way of the lip seal.

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DragBikeMike

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Re: Oil leak on the drive pulley
Reply #20 - 04/10/23 at 12:34:31

Hey Ruttly, although I am capable of screwing up one of those thin webs, I have not pulled it off yet. But rest assured, I've broken all sorts of stuff over the years. Even drilled a hole in my hand years ago. Oooooooooo! That hurt.

Is there any other way to learn stuff? Can't beat a good screwup. That lesson is cast in concrete. Will never forget it (I hope).

Good luck Gerrit. Be sure to fill us in.

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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5113 Manteca , CA Gender:	Re: Oil leak on the drive pulley Reply #21 - 04/10/23 at 22:27:08 I’ve seen that before , watched a guy drill a hole in his finger. He barely reacted , it went right thru his finger , he seemed pretty calm till he put it in reverse to get it out , it came right out. Then he passed out , almost his knees buckled a few people caught him. Blood , flesh , oh the humanity !
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gerrit650

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Re: Oil leak on the drive pulley
Reply #22 - 04/11/23 at 06:31:13

Thank you all for the replies.
The pulley nut came off too easy,[after I got ready with big bars and 3/4" sockets Grin

] and the pulley is wobbly on the shaft.
I assume the shaft is okay cause it is made of harder steel than the pulley.
Do I need a new pulley or a good used one?

Oil leak. There is dried oil/dirt in the back of the pulley as well as on other parts around it. It looks like the oil came from between the spacer and the shaft, so that would be the o-ring inside the spacer?
How do I pull that spacer out?

And it would be a good idea to replace the seal now indeed.
I assume I can pull/break it out of there and push a new one in from the outside of the trans mission?

I tried to add more pics but the max size is 2048 KB?
I am not that computer savvy either, so bear with me.

Thanks again for all your help.

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gerrit650 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 14 Antigonish Nova Scotia Canada Gender:	Re: Oil leak on the drive pulley Reply #23 - 04/11/23 at 06:45:14 Oops, wrong picture
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DragBikeMike

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Re: Oil leak on the drive pulley
Reply #24 - 04/11/23 at 15:07:54

"Do I need a new pulley or a good used one?"

You need to inspect both the pulley and the shaft. The splines on both components wear out when the pulley nut is loose. Figure out how to post clear pictures and post photos of the pulley splines and the shaft splines.

"How do I pull that spacer out?"

The spacers can be tough to remove. I use a stainless-steel worm clamp to protect the spacer. Tighten the clamp on the spacer, then you can pry on the clamp. Those o-rings have a good grip on the shaft so the spacer can be very difficult to get out.

As far as posting pictures, I find it helps a lot to load the photos off my iPad on to my PC. Then, I use the "open with" feature (right click) to open the photo using a program called "snipping tool". That snipping tool program seems to be on all of my PCs. Guess it comes with Windows. Use the cropping feature to zero in on the feature you want to display and save the photo. That brings the size of the file waaaaaaaay down, and also enhances the feature you are trying to display. If you can post clear, bright photos, we can help you.

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gerrit650 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 14 Antigonish Nova Scotia Canada Gender:	Re: Oil leak on the drive pulley Reply #25 - 04/11/23 at 16:21:15 I was able to get the spacer off, thanks! I think I can post 2 pics. I do think both shaft and pulley have some wear. I would not like to replace that shaft . What options do I have? And I will replace o-ring and seal. Thanks Gerrit.
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gerrit650 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 14 Antigonish Nova Scotia Canada Gender:	Re: Oil leak on the drive pulley Reply #26 - 04/11/23 at 16:22:12 shaft
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DragBikeMike

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Re: Oil leak on the drive pulley
Reply #27 - 04/12/23 at 11:30:01

Your pictures are getting much better.

The spines on your pulley look OK but it's hard to tell from the angle of the photo. The transmission output shaft is another story. It has a lot of wear. Changing that shaft is a big job. It requires complete engine disassembly. You will need some special tools and skills.

Another option is to reinstall the pulley using Loctite 660. That will pretty much make the thing close to impossible to remove without using a lot of heat. You best make sure you have everything assembled correctly before you throw on the pulley and cinch down the nut. The 660 Loctite should be used in conjunction with the appropriate primer/activator. Google "Loctite 660" and you can find all sorts of info and videos.

Another option would be to install one of Dave's 25T pulleys along with a shortened pulley spacer. That will provide a few more millimeters of spline engagement. I would use the Loctite 660 along with the additional spline engagement to provide the best possible installation on those worn transmission shaft splines.

This link will give you some info on the 25T pulley installation.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1675564067

Keep those pictures comin.

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Re: Oil leak on the drive pulley
Reply #28 - 04/12/23 at 15:28:52

DragBikeMike wrote on 04/12/23 at 11:30:01:

The spines on your pulley look OK but it's hard to tell from the angle of the photo. The transmission output shaft is another story. It has a lot of wear. Changing that shaft is a big job. It requires complete engine disassembly. You will need some special tools and skills.

To me the pulley splines look damaged too.
you should be able to measure the top and bottom of the splines so we can compare

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Oil leak on the drive pulley Reply #29 - 04/12/23 at 15:53:13 It's caliper time
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