02 - 04 An650 Primary spline adapter add on.

[Dave_J]

If you have a 05 and up 650 this does not matter to you. But all 02 (Europe and other than USA), 03 and 04 650's have a small Primary input shaft adapter. This is about half of that "Deiseling" noise you hear. These small splines are failing and it takes out the engine flywheel with it. Now it costs more to fix than the bike is worth.

I bet I could have a machine shop mill out a mild steel or bronze slug to make an adapter that would slide in the primary input shaft hole from the left side, under that cover just for the 02-04 An650's. You would need a longer bolt with this new "Add On" adapter, part of a kit if made. The OEM input spline adapter only ingages half the splines and by adding a longer splined adapter it would solve this big problem. Basicly to do this you would remove just the bolt that holds the OEM adapter, slide this "new add on" adapter in and bolt it on with a longer bolt, replace cover.....

I would need the amount of people that would want this. I also would not charge anything but the total cost per item. We are a small group so I can not make a killing off of ya all.

[Jim]

i'm in

[malahy1501]

I'm in also...just as long as the "wrenching" can be accomplished by someone like me who barely knows which end of the wrench to hold

Bill

[wldbill]

Sign me up, and I second the motion made by malahy1501; I can do simple mechanical stuff with enough coaching...

[Dave_J]

I'll call my machine shop and see if he wantsto do this or knows of a shop that can do a small batch. I imagin it would take about 10 to keep the cost low.

I also wonder if this add on adapter could be made from a phenolic resin or a heat resistent nylon type material.

[scootervibe]

I might be interested if depending upon costs and difficulty of adding the part. Would need some more detailed info to make that decision. I would love to extend the possible life of my scoot, but, can we be sure that this "mod" doesn't have the potential to cause problems?

Rick.

[Keith Frye]

I'm in (if not too hard to install.

[Dave_J]

Rick, on the left side of the engine just infront of the clutch is a cover held on by two bolts. If you remove that cover you can see a hollow cavity with a bolt head about 3 inches in. You will also see that the hollow is female splined out towards the cover. On the 05 up CVT's this cover is deeper and an outer male splined adapter is bolted on using those splines that are unused in the earler 650's. My thoughts are to just copy that design but in the smaller size splines of the 02-04 CVT. It should not have any ill effects, but I can not make any guarantee's or warranties. All it should do is stablize the Primary input a bit better and give it a tighter grip using all the female splines. (I hate putting gender in this but that is how its called out.)

[Dave_J]

The whole problem on these 02 to 04 CVTs is they made the splined male adapter both too short and not enough in diameter. (keep your thoughts clean boys) But in 2005 model year Suzuki pulled thier heads out their backsides (POP) and made the splines in a larger diameter and added the outer splined adapter. My guess is it made the whole primary input many 100's percent stronger.

If they had just added the outer adapter we could retro fit it but they did two fixes at once.

[scootervibe]

Thanks for that info DaveJ, I still would want a ballpark on the likely cost , but, I'm interested. I think that you potentially have many that would be interested in this , but, only after a trial run of someone that has done this and put on a few K miles with no ill effects. JMO. Sure would be great to have the "dieseling" noise damped down a bit, and alleviate some of that back of the mind questioning of "do I have one of the problem ones". Keep us posted on what you come up with. Thanks.

Rick.

[Dave_J]

I'll be working on this on Monday, my day off.

[The Scootist]

I'd be interested in this modification. The best material would likely be the same as used for the newer design primary spline adapter.

[wldbill]

Waiting patiently...

[Dave_J]

Sorry guys and gals. I have tried to call the machine shop I deal with for my hot rods but got busy signal or rings to Voice Mail. I have tried to do the VM tag with them before, not good. I will go down in person on Monday if I can. I have been out sick, still from my accedent 16 months ago and have like I said tried to call them but could not go down in person.

[scootervibe]

. Bump. Is this idea dead Dave?
Rick.

[Dave_J]

Rick and all, I am still trying to get the machine shop owner to call me back. This is prime time at machine shops as the NHRA, IHRA IMSA.... seasons are starting to kick off and everyone that waited all winter to build an engine are now jumping through their backsides tring to get work done. In December I dropped off two engines for overboring and milling, 3 day turn-around. Go Figure. I'll leave him another VM as they never answer. Or I may try a smaller (read that as HUNGRY) shop.

I have not forgot about this but it has become back burner due to work and upcomming weddings.

[scootervibe]

. OK, backburner works. Thanks for the update. I am intrigued by the idea.
Rick.