[Lennon]

Well there was a slight rattling sound that I could only hear with my helmet off, but suddenly it made a rumbling noise and when I took the left side tupperware off the primary bolt- came unscrewed and drilled its way through the cover and the inner input gear had also come out, the bolts thread is stripped, the scooter is still running without this bolt and gear, well I just rode it a few meters to put it in the garage.
What is the function of this gear and bolt? AN650 K6

 

[MJR]

If you are reffering to the primary shaft bolt it holds the CVT primary shaft in place in it's bearing and the adapter in.

 

[joe 90]

cant see how the bike rides without the gear in there :?:

 

[Fatjock]

Pictures would help clarify what's actually being discussed.

 

[MJR]

cant see how the bike rides without the gear in there :?:

Cause the CVT input shaft splines into the engine driven gear.

 

[Dave_J]

This has been reported on a few 05 and up. The 05 up do not have an adapter on the CVT side like a 02-04, the CVT from a 02 to 12 will slide into a 06 and then the left side adapter and long bolt will bolt it up.

Lennon, you may just order a new bolt and put a bit of Permatex Thread Locker Blue on the threads and screw it in real snug. And a new cover too. The threads in the CVT may not be stripped, the bolt may have been bouncing around some. http://www.permatex.com/products/produc ... eadlockers

 

[Lennon]

So this is what happened, all I am asking is how does the bike still run and I don't get why you have a gear bolted down unless to stop it turning???????

 

[MJR]

So this is what happened, all I am asking is how does the bike still run and I don't get why you have a gear bolted down unless to stop it turning???????

It holds the CVT primary shaft into it's bearing in the CVT case. It holds two spinning parts together (CVT primary shaft and engine driven gear). Looks like the tip of the threads are a bit buggered. New bolt, see how it threads in by hand and go from there. Blue locktite would help.

Interesting on that first photo there's the engine guard I've seen in service books but never in person cause the US ones don't have them from what I've seen.

 

[Lennon]

Yep MJR the bolts thread is completely stripped, this is actually a Skywave for the Japanese market, don't know how it got here in SA.

 

[Dave_J]

I think the bolt threads got JANGLED when it got loose and buggered up the tip bouncing around on the splines. Jangled = http://www.google.com/#hl=en&sugexp=les ... 80&bih=674

 

[MJR]

I think the bolt threads got JANGLED when it got loose and buggered up the tip bouncing around on the splines.

Most likely since if it were still in there then it wouldn't be rattling. At least that's the good thing that the threads in the primary shaft should be fine.

 

[Lennon]

Ok just for interest'
I want to compare prices.
Today the local Suzuki shop collected my Burgman for repair, the cost for collection was equivalent to $25 US. the distance to the workshop from my house is 10Km sorry 6.21Miles.
On Monday they will assess the damage and contact me.

 

[Dave_J]

The $25 equivalent is average for towing. Its the price that the dealer will hit you for that will shock you. This is one of the areas that "Self Help" is a good tool to have if you have the knowledge and tools to do the job. We, the forum, is the knowledge base for about 90% of what can be done at home. Being you are in RSA, getting the parts may be harder from a dealer.

 

[Lennon]

The dealer is normally pretty good with obtaining parts, but I do not have the time or the correct tools for this kind of repair, so I have left it in their hands, I know I am going to have a shock when I see there quote for repair, but they have basically got you over a barrel here, as they are the one and only Suzuki dealer anywhere near me and all the other bike repair places I am not too happy with. (I have had experience of the small bike shops workmanship)

 

[ErikDK]

What special tools are you referring to?

AFAIK it's just a couple of sockets and a torque wrench.

As for the parts themselves, my guess is it won't cost you more to order them directly online from Asia or Europe, wherever is more common in RSA, as you will have direct information about shipping status, and not bound by the dealer and RSA Suzuki agent's hidden agendas for the former to do more profitable work and for the latter to save shipping costs by waiting until the shipping container is full.

 

[Lennon]

The Suzuki repair center has just phoned me to say that all that was required was to replace the primary drive gear bolt :thumbup: , and the skywave is as good as new , I'll make a plan to collect it tomorrow (Friday) too late to get there today.

 

[Ken]

Hopefully they used blue thread locker and replaced the cover. Repair cost should be very reasonable. Great to hear it was not a major problem.

 

[Dave_J]

The Suzuki repair center has just phoned me to say that all that was required was to replace the primary drive gear bolt :thumbup: , and the skywave is as good as new , I'll make a plan to collect it tomorrow (Friday) too late to get there today.

Thats about what I thought would happen. I'd have bet $10 in equivalent RSA money that it was just the bolt rattling around that gummed up the threads. Good news for sure. :cheers:

 

[Lennon]

Cost just for interest was R1048.12 that is $118.78 for the collection of scooter, replace bolt and cover, test bike, and replace spark plugs, just because I have not changed them before. :thumbup: :thumbup: Can't wait to go collect tomorrow, do not like driving a cage, plus it's SUMMER here

 

[Dave_J]

Thats a good deal for the amount of work and parts. Would be about double here.