NHTSA Complaint #10180670 — 2006 SUZUKI SV1000S

LOUD ABNORMAL KNOCKING SOUND COMING FROM ENGINE WITH CLUTCH LEVER RELEASED. SAME SOUND NEARLY INAUDIBLE WITH CLUTCH LEVER PULLED IN. PRIMARY DRIVE NUT ON CRANKSHAFT THAT SECURES PRIMARY DRIVE GEAR ASSEMBLY LOOSENED AND PARTIALLY UNTHREADED. NUT THEN MAKES WITH CONTACT WITH THE INNER RIGHT HAND ENGINE CASE AND RUBS. THE PRIMARY DRIVE GEAR IS THEN ALLOWED TO SLIDE ON THE CRANKSHAFT OUTWARDS TOWARDS THE CLUTCH ASSEMBLY AND MAKES CONTACT, THE PRIMARY DRIVE GEAR SPRING WASHER IS THEN BROKEN ALLOWING THE PRIMARY DRIVE GEAR ASSEMBLY TO SEPERATE AND LET THE INTERNAL SPRINGS FALL OUT. VARIOUS PIECES OF METAL FRAGMENTS CAN FALL INTO THE OIL SUMP. POSSIBILITY OF CLUTCH DRIVEN GEAR DAMAGE AS WELL AS CAMSHAFT DRIVE GEAR DAMAGE OR ENGINE FAILURE IF LEFT UNCHECKED. PRIMARY DRIVE GEAR SPRINGS AND SPRING WASHERS REPLACED. PRIMARY DRIVE GEAR ASSEMBLY NUT TORQUED TO SPECIFICATION. REMOVE BROKEN PARTS FROM OIL SUMP IF PRESENT. REPLACE CRANKCASE COVER GASKET, ENGINE OIL, AND COOLANT.