2009 Suzuki VL800

MAKING A DOWNSHIFT FROM 3RD TO 2ND AROUND A CORNER I APPLIED THROTTLE THEN A BIG CLUNK OCCURRED AND I LOST POWER TO MY REAR DRIVE. I WAS ABLE TO MAKE IT TO THE SIDE OF THE ROAD, ELUDING TRAFFIC TO MOVE TO THE RIGHT LANE. UPON INVESTIGATION I'VE FOUND OUT THE PROBLEM TO BE THE FINAL DRIVE PROPELLER GEAR AND THE COUPLING WERE RUSTED AND TOTALLY WORN OUT. THIS JOINT HAD NEVER BEEN LUBED DURING ORIGINAL MANUFACTURING ASSEMBLY. THIS LACK OF LUBE HAS CAUSED THE SHAFT TO RUST CAUSING THE FAILURE. THE GREASE CANNOT BE APPLIED UNLESS THE FINAL DRIVE IS TOTALLY REMOVED. THIS IS A KNOWN PROBLEM WITH THE 05-09 MODEL YEARS AS EVIDENCE BY A SIMPLE INTERNET SEARCH. NO RECALL HAS BEEN ISSUED YET. THE COST OF THE CHANGE IS AROUND $600 - $800 DOLLARS BUT THIS DEFFECT CAN CERTAINLY CAUSE AN ACCIDENT FOR THE LOSS OF POWER WHILE OPERATING THE MOTORCYCLE ON THE HIGHWAY.

COMING AROUND A CORNER UP A HILL I APPLIED THROTTLE TO GO UP HILL. A LARGE CLUNK OCCURRED AND I LOST ALL FORWARD ABILITY. NOT HAVING POWER I BARELY MADE IT TO THE SIDE OF THE ROAD ALMOST GETTING HIT. I SWERVED TO AVOID A CAR AND WENT DOWN. NOTHING OTHER THAN MINOR SCRAPES AS A RESULT. UPON DETERMINING THE PROBLEM TO BE THE FINAL DRIVE I REMOVED THE PART AND FOUND IT WAS NEVER LUBED DURING ASSEMBLY. THIS CAUSED THE SHAFT TO RUST CAUSING THE FAILURE. THERE IS NO WAY TO APPLY GREASE TO THE PART WITHOUT ENTERING THE NON MAINTENANCE AREA OF THE FINAL DRIVE. THIS IS A KNOWN PROBLEM WITH THE 05-09 MODEL YEARS AS EVIDENCE BY A SIMPLE INTERNET SEARCH. NO RECALL HAS BEEN ISSUED YET. I WAS LUCKY AND MADE IT OUT OF TRAFFIC, OTHERS MAY NOT BE AS LUCKY. *TR