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post #1 of 40 Old 05-18-2010, 09:27 PM Thread Starter
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A Countersprocket Nut Story, (Photos)

Last Friday, I left Mount Desert Island, Maine with my GPS set for Milton Mills, NH to spend the night with an old riding buddy of mine; Scott. One my way South, I ran a quick errand in Portland. I arrived at Scott's in time to head out for dinner.

On Saturday morning, Scott and I rode our motorcycles up to the Whitehorse Gear Open House event located in East Conway, NH. We spent about 2 hrs there, talking with riders, checking out bikes and munching on plate fulls of fantastic, (FREE!!!!), food, (It was one heck of an Open House!).

Around noon-time, Scott and I headed up Rt 113, (for those of you who know, you are grinning, right?), to Gorham, NH. At the intersection of Rt 113 and Rt 2, Scott and I parted ways; he headed back down Rt 113 for Milton Mills and I started cutting across NH, VT and up into Québec. I was shooting for Magog, Québec and Rancho Du Spaghetti, where I have stayed four times before, (I really like this place!).

Sunday morning, I cut across lots of farm country, using as many dirt roads as I could find, (I know this area fairly well now). I crossed back into Maine around 11:30 am at the Corburn Gore crossing. Because I was "early", I decided to extend my journey by picking up the Gold Brook Road, (just South of Natanis Pond), and ride that up to the Spencer Lake Road and out to Rt 201 at Lake Parlin, (about 40 miles of dirt logging roads).

It was about 1:00pm when I got to Rt 201, just South of Jackman. I decided to do more dirt riding. I rode down to The Forks and picked up the Moxie Pond Rd, then the Brouchu Rd and rode that all the way to Greenville. Once in Greenville, it was time to "make hay" for home. That was about 80 miles of "up-on-the-pegs" riding. At a given point, I was about 20 miles from any help...........

(The total mileage was about 755 miles for the weekend.)

Yesterday, (Monday), I decided it was time to remove the lackluster Metzeler Karoos that I had won last year for being the "high mileage" contest winner at my local dealership. I was hoping to get more mileage out of these tires compared to the TKC-80s that I like to run. I'm on a "thin edge" and mounted up a used, front and rear, set of Anakees I had hanging around.

While the rear wheel was off, I decided to clean the chain. After completing that task, I mounted the rear wheel into the swingarm and then gave the wheel a "test spin" with my hand. Something didn't sound right, nor did it feel right.

I sighted down the chain towards the front sprocket. When I was cleaning the chain, the chain jumped off the countersprocket. I was now faced with a choice; drop the rear wheel, or remove the countersprocket cover so that I could get the chain back on to the countersprocket.

I don't know why, but I chose to remove the sprocket cover.

This is what I found.


The countersprocket nut had loosened up and backed off the threads enough that it was cutting through the clutch release mechanism.

Here is the washer.


Take a close look, (Greywolf is going to pick up immediately on what was going on.). When I installed my last set of sprockets and chain, I also installed a new countersprocket washer. I also made the decision, (after torquing down the countersprocket nut), NOT to fold the edge of the washer over to lock the nut in place.

Bad choice.

I used my Dremel tool to clean up the washer as best as I could, and reassembled everything. AND, folded the washer down over the nut. (I will get a new washer and clutch release mechanism.......after I get new sprockets..........and new tires...........)


While I was putting the bike back together, I got to thinking about the 3 1/2 miles that I had to push my bike out of the woods last year when I hydrolocked the motor when I dumped the bike in a big mud puddle. If the countersprocket nut had backed off farther and had completely cut through the clutch release mechanism, I would still be in the woods today..........still pushing.

So everyone, please check your nuts before you leave home.

B.

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
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post #2 of 40 Old 05-18-2010, 09:35 PM
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Nuts

Just checked my nuts and they are great. The bike is in the garage, will look at that in the am. Seriously, will check it.

05 DL 650 :
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post #3 of 40 Old 05-18-2010, 09:49 PM
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Quote:
Originally Posted by Black Lab View Post
So everyone, please check your nuts before you leave home.
Or have somebody check them for you.

It looks like the washer was not over the splines when the nut got to it. It's a good idea to make sure the washer and nut are concentric before tightening the nut. Folding the washer onto the nut probably would not have prevented the loosening because the tabs were not locked into the splines and the nut didn't bear against the full face of the washer. The act of folding might have made it obvious the washer wasn't centered though.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
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post #4 of 40 Old 05-18-2010, 11:45 PM
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Barry, get an inspection port in your sprocket cover quick



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post #5 of 40 Old 05-18-2010, 11:49 PM
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Quote:
Originally Posted by greywolf View Post
Or have somebody check them for you.
.
good advice, it prolly would have prevented my rear caliper from putting a 6" gash in the rear wheel of my SV650



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post #6 of 40 Old 05-19-2010, 04:27 AM Thread Starter
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Quote:
Originally Posted by randyo View Post
Barry, get an inspection port in your sprocket cover quick
HA!!! You are absolutely correct, sir!!!!

Randyo and I had a chance to briefly chat at the Whitehorse Gear Open House. One idea that he shared with me is something that he has done on his bike. He drilled a 1" diameter hole through his bike's countersprocket cover and installed a rubber plug. The rubber plug can be removed so that the hole becomes an inspection port to check the front sprocket. The rubber plug is of the kind that you find in the doorway area of a Ford Windstar. His Ford Windstar has one less rubber plug.......

I also own a Ford Windstar.......

Thank you for the reminder, Randyo!

B.

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
1942, Beryl Markham: "West With the Night"
"You can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing"
James Baldwin "Across Islands and Oceans"
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post #7 of 40 Old 05-19-2010, 04:39 AM Thread Starter
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Quote:
Originally Posted by greywolf View Post
Or have somebody check them for you.

It looks like the washer was not over the splines when the nut got to it. It's a good idea to make sure the washer and nut are concentric before tightening the nut. Folding the washer onto the nut probably would not have prevented the loosening because the tabs were not locked into the splines and the nut didn't bear against the full face of the washer. The act of folding might have made it obvious the washer wasn't centered though.
Pat, everything was in its proper place when I tightened it. Here is a photograph of the same setup back in 2009. You will notice that the washer is not folded over the nut. Look at the threads of the countershaft, they stick out BEYOND the end of the nut compared to the photograph above. The splines of the washer got pounded out of shape by bouncing around on the countershaft. There was quite a bit of slop between the nut and the engine case!



My guess is, there is something like 3,000 miles ridden with everything loose. That's why I am not too concerned about it and reassembled everything. But, will order parts soon.

(I also used Blue threadlocker as well on the threads.).

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
1942, Beryl Markham: "West With the Night"
"You can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing"
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post #8 of 40 Old 05-19-2010, 08:34 AM
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Just curious, what did you torque the nut down to when the front sprocket was off last? It looks like the actual nut has a locking ring on it that is coming off. I could be wrong though. I don't remember if my 05 has a regular nut or a self locking one. You said it though, if that would have come completely off it would have not been pretty.

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post #9 of 40 Old 05-19-2010, 08:50 AM
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Quote:
Originally Posted by CJH View Post
Just curious, what did you torque the nut down to when the front sprocket was off last? It looks like the actual nut has a locking ring on it that is coming off. I could be wrong though. I don't remember if my 05 has a regular nut or a self locking one. You said it though, if that would have come completely off it would have not been pretty.
You have to peen that locking washer/ring over against the flats of the counter sprocket nut for it to work. Your '05 is the same.

-Tom (DL650AL2) (KA1TOX) (E-I-E-I-O)

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post #10 of 40 Old 05-19-2010, 09:21 AM
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Crazy! I'm shocked the counter-sprocket nut budged, it's torque to 105 ft lbs.

I'll tell you this, no eternal reward will forgive us now for wasting the dawn.
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