K8 Countersprocket FROM HELL!!!!!!!!!!!!

[Warchild]

Jeeze.... this just shouldn't be that much trauma...... <_<

At 31,000 miles, the Hayabusa's OEM chain is well past it's useful service life. So I go out to the garage to install new chain/sprockets. I've only done this a million times on many different bikes. But NEVER had I had a countersprocket that refused to budge a single millimeter like the one on this K8! :angry2:

The issue is that the countersprocket is retained not only by a 36mm jam-nut, Suzuki also decided to slap on a massive dollop of locktite.... RED loctite! :blink: :blink: :blink:

Below, in the center of the countersprocket, you can see the speedometer sensor rotor that is retained by an allen-head bolt. That came off fairly easy. Not so that ginormous 36mm nut.... even using a beefy 1/2" breaker bar, it didn't even twitch!

So.... tonight, I will go medieval on its ***, and apply a little heat from a small propane torch, and then use a 2-foot steel pipe extension on the long-handled 1/2" beaker bar. I don't own a 1/2" air gun, or I would try that first.

I am reasonably sure after I go through this exercise the first time, subsequent maintenance action here will go much smoother. This problem is actually typical for components assembled at the factory... they are frequently tighten to much more than the specified Service Manual torque settings. The 36mm countersprocket nut calls for 105ft-lbs... I was well, well over that several times trying to remove the stubborn biotch....

Regardless, you are coming off tonight, Mr. Countersprocket... one way, or another! :butcher:

 

[garauld]

I suggest using a hand hammer impact tool with a bit of heat - you may have one in your toolbox near the bottom that you used a long while back for removing those darn phillips head engine screws from your:

:yahoo:

 

[Duezzer]

Hi there

Ran into the same problem on an old bike I was working on

The only thing that worked was an impact driver and a little head

I had a 2' snipe on a 1/2' strong arm and mine would not budge

Talked with a tech and he said to use the impact becouse if you pull to hard you can damage other components within the bike

The impact works like a hammer and is much easier on the adjacent components

Later

 

[Warchild]

Talked with a tech and he said to use the impact becouse if you pull to hard you can damage other components within the bike

I could see that perspective if one left the transmission in gear.

But you never want to do that... I use the old tried-n-true method: a large wood broom handle to trap the rear wheel by the swingarm, PLUS having the bride heavily step on the rear brake. This combo results in no movement of the sprocket at all.... but it still didn't budge last night.

I do have a large punch (a brass drift, actually) that I should try using to give a few sharp raps on the face of the nut in several places after applying a bit of heat.

 

[beerme]

Yer doin' it wrong. S'posed to cuss at it, see.

 

[LDRydr]

Lefty-loosie, righty-tighty :dribble:

 

[radman]

Your party, but I would definitely head down to the local shop-any shop, have 'em slap an impact on there, then just snug it up for the trip home. I'm sure you know this, but impacts can loosen nuts with less force and potential damage than an equivalent force applied any other way, not to mention far less drama. And I'm not so sure you won't end up there anyway, even a breaker bar mit pipen is no guarantee you'll get it off.

 

[Duezzer]

That there cussin' - That's the ticket

Broom handle good - Axe Handle Better

Impact much less intrusive - they make electric ones now but watch the torq - some are week - get a big-un

Go spend your kids inheritance or while the helper is standing on the break go to the store with their credit card B)

Later

 

[vectervp1]

Yer doin' it wrong. S'posed to cuss at it, see.

Not to mention drink. How many beers did you have prior to, during and after the project? Perhaps you were not inebriated enough to take on the task.

 

[Wolfhound]

I have a good old SEARS 1/2 inch electric impact/sockets that are awesome . . . .

 

[Geezer]

Impact gun and heat. Much less expensive than any parts you may break while trying to muscle it. And once you have a good impact gun you'll wonder how you ever got along without it.

 

[wfooshee]

Impact. Do it.

Even a cheap one that you'd be ashamed to be seen with would get it done instantly.

Even with a compressor small enough that you could only run the wrench 3 or 4 seconds at a time.

It would be better than all the other crap you're trying to deal with.

But: never ever ever assemble with the impact wrench.

Go to some auto parts store and get the cheapest 1/2" air wrench you can find. If you don't have air at the house, then get the cheapest little compressor they've got that'll tank up to 120 or 150 pounds. Use good hose, not the little yellow coil hose.

Even if you had to buy all of that from scratch, you should come in under a hundred bucks if you get stuff on sale. Driving around getting it, spending the money, and getting the sprocket off. Still faster and cheaper (if you value your time) than the other efforts you're describing.

Unless you're working on cars, too, you won't need any more than this, but once in a while you'll be glad you have them.

 

[Wolfhound]

C'mon guys, This is Warchild you're replying to....He knows the impact inside & out fer chrissakes . . .

 

[mdisher]

This aught to do it...

https://www.overstock.com/Home-Garden/TD-In...ci_sku=11382044

$57.00

 

[twistedcricket]

You could probably buy all of that at your local Harbor Freight store. Great place for "one-time-cheap" tools. If you break 'em generally they'll exchange them.. If you don't, you get at least a few more uses out of them.

If'n you go this route, you'll obviously want to get impact sockets too... don't ask how I know...

 

[Warchild]

Ya know, upon further review.... a Harbor Freight cheapo electric impact might indeed be the way to fly, instead of dicking around with heat/pipe extension..... I'll check it out.....

 

[chrisflock]

I once was trying to remove a through-bolt for the shock on a pickup. I had a nice, long pipe slid over a breaker bar on that sucker, and I couldn't budge it. I came up with a brilliant idea, use a jack to push up on the bar (because of location, I couldn't swing from the other side and step on the bar.

With the bar basically horizontal, I slipped the jack under it and started pumping. I couldn't believe it, the pipe was moving!

Then I looked at the truck. All I was doing was lift the truck off the ground.

Rolled over to my dad's house, slapped his air wrench on it, didn't even plug in the compressor, it had like 70 lbs in it from last use...

Bzzrt. Nut popped right off.

I must have loosened it up...

 

[Bogie]

i would just go ahead and sell that Susucki!!

 

[Warchild]

Mission Accomplished, gentlemen! Harbor Freight 1/2" Electric Uber-Heavy Duty Impact Wrench, on sale for $39.99!!!

[SIZE=14pt]**Sha-Zaam**!!![/SIZE]

BTW, that is NOT corrosion on those threads.... that's dried red loctite splooge... :angry: :angry: :angry: