Copy of the original large gear servo throttle Muffler for Suzuki Boulevard M109R/C109R or Intruder VZR1800/M1800R/VLR1800 +VIDEO!
A replica of the original large gear servo throttle muffler for Suzuki Boulevard M109R/C109R or Intruder VZR1800/M1800R/VLR1800 motorcycles of all model years.
There is no factory item number, because this gear is not sold by the factory as a separate part and is considered part of a "conditionally" non-collapsible assembly with articles: 33970-48G00-000 / 33970- 48G01-000 (servo assembly - ACTUATOR ASSI, EXHAUST CONTROL).
Peculiarities:
The gear is used to repair the servo and is made by us on a 3D printer from a composite material that has an identical shape and hardness to the original. The only difference is the color of the material, which does not affect the functionality of the product. We are also the only manufacturer of these gears and other parts for the throttle servo of the above mentioned motorcycles.
Specification:
This is the main gear, which is located on a metal pin, just under the top cover of the servo, and in order to get to it, you need to open the "box" of the device. The original gear has a white color and very often one or more faces are missing on it.
Package contents:
The gear is supplied complete with special crimping rollers (see the instructions below).
Gear Replacement Instructions:
Important!!! When opening the servo, BE SURE to fix the metal hook of the cables in a vice or clamp it with an adjustable wrench, as described in the video below! Only after fixing the hook, unscrew the central screw! Do the same during assembly, otherwise you will tear off the teeth of the main gear yourself!!!
The gear is pressed onto a standard metal pin. It is not difficult to remove the old gear, but you need to press the new one according to the instructions that you will read below.
1) Disassemble the servo and remove the old pinion. Then release the pin from the remnants of the old gear, first removing the plates with the probes.
2) Fix the pin in the vise and heat it up. Then, on the hot pin, put one of the rollers corresponding to its side. Turn the pin over, warm it up and repeat the procedure of putting on the second roller (scheme No. 1: photos 1 and 2). Make sure that both rollers fit tightly onto the pin now, but all the way to the end.
SCHEME No. 1
2) Install the new gear (diagram No. 2: part No. 3) in the main roller (diagram No. 2: part No. 2).
SCHEME No. 2
3) Insert the pin with the thin side into the main roller, preheat it (for example, with a lighter) and slightly sink it with the second roller (scheme No. 2: part number 1). Do not apply too much pressure so as not to break the gear, pushing the pin about a third or a quarter into the depth of the seat. Then remove the pin and clean the resin residues trapped in the seat from the grooves squeezed out by the pin inside the seat. The procedure must be repeated 3-4 times so that the pin fits snugly to the base, and no debris forms in the seat. The last pass can be performed without removing the pin.
The procedure of primary "dipping" of the pin into the base of the gear is also allowed using a vise or pliers (scheme No. 1: photos 2 and 3).
Do everything very carefully, because damage to the gear when replacing it is not a warranty case!
4) Pins in different years of production come with teeth on the seat and without. If your pin has no teeth, it is better to put it on superglue at the final stage. For reliability, it can be mounted on superglue and a gear with teeth...
5) Do not forget to return the plates with the probes to the new gear!
Why is a working servo important and how to save it on Suzuki M109R/M1800R or C109R/VLR1800.
Delivery:
Delivery is carried out throughout Russia, to the countries of the former Soviet republics and Europe. If you wish, you can choose to send by regular mail, EMS, or another shipping company upon order approval. The shipping cost is calculated upon receipt of information about the recipient's city and depends on the size and weight of the cargo.
It is also possible to pick up an order from Pushkino, Moscow region, or deliver it by courier within the MKAD (subject to agreement).
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