Drive Shaft Failure at Traffic Signal - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #1 of 2 (permalink) Old 08-26-2019, 11:13 PM Thread Starter
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Drive Shaft Failure at Traffic Signal

Hello everyone

I have an 06 c50 with 32k miles and the shaft and final drive coupler splines are completely rusted out and flat. The failure happened at a red light luckily and was driving completely fine up until the part where I let out the clutch and hurt massive grinding coming from the rear end. Trying to take it all apart now so that I can get all the correct Parts ordered up. I've been through all these threads about this issue and cannot find any detail with pictures on how to remove the coupling nut correctly and easily without purchasing the special coupling holder tool from the dealership.

I just downloaded the service manual and says to unlock the nut with a chisel but not sure how to do that. I've taken a few whacks at it with a small chisel and hammer and can't get the lock tab to pop up enough to take the nut off. Also says to use a special tool drive coupling holder tool. Not gonna buy this special tool for this one use. Any suggestions from the ones who've had to remove the coupling nut?? I've got everything apart and cleaned up except I can't get this coupling nut off the final drive Unit. Help please.

Thanks in advance

Brian

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post #2 of 2 (permalink) Old 08-27-2019, 12:18 PM
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This is a bit of a known issue with my "big bike", a Honda Valkyrie. It's generally thought the root cause of the spline failure between the driveshaft and final drive cup is the boot on the swingarm to the trans output shaft getting hard with age and allowing water to seep in, which then runs down the driveshaft tunnel and gets trapped. Seems much more common in more humid/rainy climates, and to a degree people that wash the bike frequently, or ride in the rain a lot. Occasionally pulling the rear drive to re-grease the splines staves this off (most shaft drive bikes do suggest greasing this occasionally in the maintenance chart, but it's widely ignored)

Anyway, the issue of getting the spline cup off is the same. No real good way to hold it, Honda says you need a special tool. It has a locking nut and is usually pretty stuck on there after 20+ years. People have a hell of a time trying to make tools, jam the drive from turning, trying to beg/borrow the special tool, ect. I haven't seen the C50 one but it sound like pretty much the same deal.

I grabbed my cordless Matco 1/2" impact (which rocks, it makes my air powered one feel anemic) and it blasted the nut loose in about half a second, no holding the drive needed. The cup then slides right off. Same to re-install. The torque spec to re-install is approximately two ugga-duggas.
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