WARNING! Engine failure possible due to incorrect assembly - SV1000 Portal
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post #1 of 239 (permalink) Old 4th December 2006, 05:21 AM Thread Starter
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Exclamation WARNING! Engine failure possible due to incorrect assembly

I don't really want to cause a panic but I feel everyone with at least a 2006+ SV to see what I came across. There have been some posts about a knock that is occuring that is not related to the original knock that the '03 owners have discussed. It has been mainly a knock that is related to clutch engagement at idle (clutch out very noisy and clutch in quiet) and sometimes a shudder type vibration when accelerating through 2.5 to 4,000 ish RPM. I think I have only really read about the 2006 owners comments about this particular sound.

The noise usually starts after about 500 miles from what I have seen. Having just put the SV away for the winter I decided I was gonna see if I could find anything irregular happening under the clutch cover. I was damn near in shock when I looked at the primary drive gear. I could see where this could have caused some abnormal noise. Eventually damage to the cam drive gear, clutch gear, and possible coolant loss into the engine area. I am finding this out with about 8,000mi on my bike. I don't want to leave you hanging but I want to post some pics up of what exactly is going. I will get them posted ASAP.

Craig
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post #2 of 239 (permalink) Old 4th December 2006, 07:16 AM Thread Starter
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Here we go...

#1 The primary drive gear nut is what caught my eye.
#2 From a different angle. This is how much it had unthreaded itself. FYI it is also a left handed thread, opposite of a normal thread. This is supposed to help keep the nut from loosening. Of course it needs to be tight in the first place, a hefty 83 Ft. Lbs.
#3 Here you can see where the primary drive gear assembly started to move off the crankshaft and rub on the inside water pump housing. It actually has worn grooves into it.
#4 I decided to take out the oil screen. When pulling it out I heard some metal clicking sound and met some resistance. That is when I looked closer and seen the primary gear spring washer. Yes, it traveled quite a ways and I am suprised it did not do any damage. (this area is directly below the clutch)
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post #3 of 239 (permalink) Old 4th December 2006, 07:21 AM Thread Starter
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#1 The spring washer pulled from below the oil screen
#2 What it should look like if it wasn't broken
#3 These springs were still in place between the two primary gears, I did find little pieces down at the oil screen though
#4 Shows how the primary is assembled
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post #4 of 239 (permalink) Old 4th December 2006, 07:27 AM Thread Starter
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#1 Can't quite figure this one out yet. The two punch marks on the primary gear and cam drive gear should line up. Well, they don't and the outer primary scissor gear can only be placed on one way I think. Nothing has moved or else the engine would not run correctly and very likely slap the pistons and valves together. The keyways are not sheared. I need to mess around with this some more to see if I can get them to line up.
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post #5 of 239 (permalink) Old 4th December 2006, 07:55 AM
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seems a poor design fault not to have either a split pin, tab washer or circlip on that nut, however looking at the pics although the nut coming loose is bad, the gears you show are locked into place with a circlip.

I wonder if suzuki take this cover off to check when you pay them £350 for a service? I doubt it.
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post #6 of 239 (permalink) Old 4th December 2006, 11:50 AM
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WOW!

Suzuki quality at its finest...


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post #7 of 239 (permalink) Old 4th December 2006, 01:20 PM
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Holy crap Craig! Thanks for your investigative technical analysis and excellent documentation. Have you contacted Suzuki about all this yet? If it's happened to yours, it's very likely many other bikes are affected. I recommend you for an instructor award.
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post #8 of 239 (permalink) Old 4th December 2006, 01:27 PM
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WOW!!

Mine has had that shudder for a few thousand miles and I just owed it to loosening up with age and miles. Kinda makes me wanna pull the cover off when I get home from work tonight. From the looks of things, I'm guessing I'll need a gasket. I'm due to change the oil and I guess I'll have to take a look see.

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post #9 of 239 (permalink) Old 4th December 2006, 03:16 PM
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Good post..if a little worrying

Think I might have a look at mine although I have no noises coming from mine at 20,000 miles.

Can't understand how the marks on the gears don't line up, they must have been assembled that way as they can't have moved.

I'd send the photos to Suzuki and ask thier opinion.

Pete.





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post #10 of 239 (permalink) Old 4th December 2006, 03:17 PM
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I just saw the image of the primary dots not lining up. This is very serious. If the cam chain idler shaft does not match up correctly this mean that your cam timing could be way off. If the primary came off and one of the cams was at partial lift the idler shaft will rotate but the crank will not causing the cams to be out of phase. I would recommend pulling the valve covers, and checking everything. Make sure it is exactly as the service manual says. When the motor is completely torn down and going back together you have to match the primary dots first, then match the cam idler gear phase, and then set the cams. I hope you have time to check this

-MS


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post #11 of 239 (permalink) Old 4th December 2006, 03:33 PM
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Ah, just noticed that the scissors gear assembly has been put together incorrectly. The three alignment holes on both gears need to line up. So it looks like you need to split the gears and reassemble with the three holes lined up. This should make things line up a bit closer. Did you just set it together? Looks like there are a few other things missing.

-MS
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post #12 of 239 (permalink) Old 4th December 2006, 03:39 PM
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Damn !

Looks like you got to it just in time. I hope this is just a single case of a loose nut and not the norm !

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post #13 of 239 (permalink) Old 4th December 2006, 04:00 PM
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I will be checking my '06 in the next day or so when I put the Gixxer shock on.

Thanks for the heads up. I have 6k miles on my SVS and haven't noticed any of the symptoms, but it will be good to check it none the less.

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post #14 of 239 (permalink) Old 4th December 2006, 04:02 PM Thread Starter
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Quote:
Originally Posted by schmidt314 View Post
Ah, just noticed that the scissors gear assembly has been put together incorrectly. The three alignment holes on both gears need to line up. So it looks like you need to split the gears and reassemble with the three holes lined up. This should make things line up a bit closer. Did you just set it together? Looks like there are a few other things missing.

-MS
That was how the scissors gear was for the most part. They are lined up in their correct positions, the outer gear is just about 1/2 tooth off cause it is not engaged on the clutch drive gear and the springs are trying to rotate the scissor gear. The primary drive gear is also held by the snap ring, which will keep it from moving out far enough to either un-mesh with clutch or cam gears. Primary and cam gears are also keyed, and they have not sheared so the gears could not have spun on the shafts. I tried to rotate the outer scissors gear to get them holes to line up another way and they will not. It just seems like if those marks were that far off it would not want to run, or would be beating the valvetrain to pieces. But the bike runs excellent.

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post #15 of 239 (permalink) Old 4th December 2006, 04:11 PM
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I can't understand why if these are 2006 models,you would want to tear them down to inspect and do repair.Are they not under warranty?I would think Suzuki would at least give consideration,and most probably would at the very least bear some of the responsibility and cost of making the situation right.Now that you have torn it apart that might voit any remaining warranty.Ride safe.........Les
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