How to Inspect Rear Drive/Shaft - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum

**Psyc0** · 11-17-2011, 10:00 AM

Link to Rusk's Tutorial

Complete with images and step by step assistance....many thanks to the creator and hoster of this helpful tutorial!

472viper · 11-17-2011, 10:53 AM

That is a good link for tire and final drive removal and reinstallation.

It is however lacking in instructions for removing the driveshaft from the final drive and lubing the drive-side splines. That is the area that causes driveshaft failure within the final drive. The Rusks's link has instructions for lubing the u-joint end of the driveshaft, people just have to remember to remove the grease seal and snapring from the final drive, remove the driveshaft, and lube with the same moly lube. This almost always necessitates replacement of the grease seal at the drive end of the driveshaft.

**Psyc0** · 11-17-2011, 10:57 AM

Quote:

Originally Posted by 472viper

That is a good link for tire and final drive removal and reinstallation.

It is however lacking in instructions for removing the driveshaft from the final drive and lubing the drive-side splines. That is the area that causes driveshaft failure within the final drive. The Rusks's link has instructions for lubing the u-joint end of the driveshaft, people just have to remember to remove the grease seal and snapring from the final drive, remove the driveshaft, and lube with the same moly lube. This almost always necessitates replacement of the grease seal at the drive end of the driveshaft.

Russ,
Do You still have some images regarding that procedure?
It'd be terrific if You could add that update to this thread!

472viper · 11-17-2011, 11:14 AM

Well, as many of those drives as I've tore down, you'd certainly think I'd have some pics wouldn't you? I looked and I don't have anything very good. I've got a drive setting on the bench that I need to reseal, I'll get some pics of the procedure and post 'em, might take me a day or two.

**Psyc0** · 11-17-2011, 11:16 AM

Quote:

Originally Posted by 472viper

Well, as many of those drives as I've tore down, you'd certainly think I'd have some pics wouldn't you? I looked and I don't have anything very good. I've got a drive setting on the bench that I need to reseal, I'll get some pics of the procedure and post 'em, might take me a day or two.

You' da man!

472viper · 11-17-2011, 08:44 PM

As luck would have it, I no longer have any C50 drives to take pics of (they were all given as wedding presents). I have a C90 drive I need to reseal, but the grease seal is different than C50.

Here is a pic of a C50 drive. I took this pic for demonstration, as the driveshaft had already been removed.

This is the coupler on the final drive that holds the drive end of the drive shaft. This is the end that fails and fails due to a lack of lubrication.

Push the grease seal off the end of the coupler with a screwdriver or punch, pushing the seal off the coupler by tapping on the screwdriver with a hammer. This grease seal should be replaced, so have a new one on hand.

Behind the grease seal is a snapring, push in on the driveshaft. There is a spring inside the coupler behind the driveshaft and you will feel that spring compress as you push in on the driveshaft. Relieving the driveshaft from the springs pressure on the snapring, will make the snapring removal alittle easier.

With the spring compressed and pressure off the snapring, remove the snapring with a snapring pliars or thin screwdriver. Suzuki recommends that you not reuse the snapring, but if I haven't bent it during removal, I have reused them.

With the snapring removed the driveshaft can be removed from the coupler, inspect the driveshaft and coupler splines for wear, lubricate with moly grease and reassemble.

A driveshaft

grease seal

snapring

driveshaft spring

final drive primary gear nut

washer

bearing stopper

coupler

Primary gear and bearing

***NO, YOU DO NOT NEED TO DISSASSEMBLE THIS FAR, FOR DEMOSTRATION AND PARTS BREAKDOWN ILLUSTRATION ONLY***

MikeYC · 11-18-2011, 03:35 PM

Needs a sticky

Mike, I stickied this when I first posted in the thread on the 17th.
~Psyc0

debo · 03-20-2012, 01:19 PM

love it.

grego · 03-20-2012, 02:47 PM

Yoo da main Russ!!!

smjones13 · 03-20-2012, 02:50 PM

My project for this weekend

Sent from my Motorcycle iPhone app

11-17-2011, 10:53 AM	#2 (permalink)
472viper Senior VR Member Join Date: Jul 2005 Location: So. Dak. Sioux Falls Posts: 23,725 Thanks: 750 Thanked 1,517 Times in 1,193 Posts	That is a good link for tire and final drive removal and reinstallation. It is however lacking in instructions for removing the driveshaft from the final drive and lubing the drive-side splines. That is the area that causes driveshaft failure within the final drive. The Rusks's link has instructions for lubing the u-joint end of the driveshaft, people just have to remember to remove the grease seal and snapring from the final drive, remove the driveshaft, and lube with the same moly lube. This almost always necessitates replacement of the grease seal at the drive end of the driveshaft. __________________ 2006 M50/C50/109fender/ SE 50 wheels and HD bags 2007 1600 Kawasaki ClassicSOLD 2008 FLHX Street Glide 105th Anniversary #1387 USAF 1973-1977 SoDak ANG 1977-2010 Run my fingers across the bars of his cage and make the little monkey dance

11-17-2011, 11:14 AM	#4 (permalink)
472viper Senior VR Member Join Date: Jul 2005 Location: So. Dak. Sioux Falls Posts: 23,725 Thanks: 750 Thanked 1,517 Times in 1,193 Posts	Well, as many of those drives as I've tore down, you'd certainly think I'd have some pics wouldn't you? I looked and I don't have anything very good. I've got a drive setting on the bench that I need to reseal, I'll get some pics of the procedure and post 'em, might take me a day or two. __________________ 2006 M50/C50/109fender/ SE 50 wheels and HD bags 2007 1600 Kawasaki ClassicSOLD 2008 FLHX Street Glide 105th Anniversary #1387 USAF 1973-1977 SoDak ANG 1977-2010 Run my fingers across the bars of his cage and make the little monkey dance

11-17-2011, 08:44 PM	#6 (permalink)
472viper Senior VR Member Join Date: Jul 2005 Location: So. Dak. Sioux Falls Posts: 23,725 Thanks: 750 Thanked 1,517 Times in 1,193 Posts	As luck would have it, I no longer have any C50 drives to take pics of (they were all given as wedding presents). I have a C90 drive I need to reseal, but the grease seal is different than C50. Here is a pic of a C50 drive. I took this pic for demonstration, as the driveshaft had already been removed. This is the coupler on the final drive that holds the drive end of the drive shaft. This is the end that fails and fails due to a lack of lubrication. Push the grease seal off the end of the coupler with a screwdriver or punch, pushing the seal off the coupler by tapping on the screwdriver with a hammer. This grease seal should be replaced, so have a new one on hand. Behind the grease seal is a snapring, push in on the driveshaft. There is a spring inside the coupler behind the driveshaft and you will feel that spring compress as you push in on the driveshaft. Relieving the driveshaft from the springs pressure on the snapring, will make the snapring removal alittle easier. With the spring compressed and pressure off the snapring, remove the snapring with a snapring pliars or thin screwdriver. Suzuki recommends that you not reuse the snapring, but if I haven't bent it during removal, I have reused them. With the snapring removed the driveshaft can be removed from the coupler, inspect the driveshaft and coupler splines for wear, lubricate with moly grease and reassemble. A driveshaft grease seal snapring driveshaft spring final drive primary gear nut washer bearing stopper coupler Primary gear and bearing *NO, YOU DO NOT NEED TO DISSASSEMBLE THIS FAR, FOR DEMOSTRATION AND PARTS BREAKDOWN ILLUSTRATION ONLY* __________________ 2006 M50/C50/109fender/ SE 50 wheels and HD bags 2007 1600 Kawasaki ClassicSOLD 2008 FLHX Street Glide 105th Anniversary #1387 USAF 1973-1977 SoDak ANG 1977-2010 Run my fingers across the bars of his cage and make the little monkey dance

11-18-2011, 03:35 PM	#7 (permalink)
MikeYC VR Member Join Date: Aug 2009 Posts: 188 Thanks: 39 Thanked 11 Times in 8 Posts	Needs a sticky Mike, I stickied this when I first posted in the thread on the 17th. ~Psyc0 __________________ 09 C50TDJ "Bella" Retired Navy Chief Petty Officer Cobra Highwaybars, Kurakyn License plate helmet lock, Bikerbrackets Helmet Lock Relocation Kit, ProGuard highway bar covers, DJ Drive, Kisantech Signalminder&Pathblazer, OEM Lightbar, Gman Bushing and Lean Angle Indicators, H-D Reflectors, Kurakyn Longhorn Dually ISO Highway Pegs, Kurakyn Clear signal lenses, Grasshopper Backrest, Spacer Jims 1.75 Spacers, Kurakyn ISO Grips, VA Lowers, Jardine Luggage rack, Wolo dual tone Air Horn.

03-20-2012, 01:19 PM	#8 (permalink)
debo Junior Member Join Date: Mar 2011 Location: Fayette, Ga Posts: 46 Thanks: 0 Thanked 2 Times in 2 Posts	love it.

03-20-2012, 02:47 PM	#9 (permalink)
grego Senior VR Member Join Date: Dec 2007 Location: Fort Worth, TX Posts: 552 Thanks: 10 Thanked 25 Times in 23 Posts	Yoo da main Russ!!!

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