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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> gear not engaging /cgi-bin/YaBB.pl?num=1095347273 Message started by tekxtc on 09/16/04 at 08:07:53 |
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Title: gear not engaging Post by tekxtc on 09/16/04 at 08:07:53 The "bulletproof" cracked :-[ I have a green 2000 with 9250 miles on it. I was riding it yesterday (out to run an errand) when all of a sudden the gear disengaged. I stopped the bike on the side of the street and tried to see whats up when I realized that no matter what I do, It will not go in any of the gears. With or without the clutch. The engine starts up. No problems. But if I depress the gear, it does not engage. It is kinda spongy. I went over the clymer and it says that I will have to remove the engine from the frame to work on the gear mechanism. Also: it does not have anything to troubleshoot anything similar. Should I just start disconnecting various things in the order mentioned in the clymer or is there some way of figuring these things out? Any and all help will be appreciated. Regards Autif |
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Title: Re: gear not engaging Post by za16866 on 09/16/04 at 10:15:14 did you check to see if the front hub is spinning..... ? i ran into this problem last year... the front hub broke .. and the output shaft just spun not turning the hub to run the belt... just a thought.... |
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Title: Re: gear not engaging Post by Autif on 09/16/04 at 20:24:04 you the man ZA. It seems like this is exactly the problem. The shaft is spinning, but hub is not when the gear is engaged. So how did you fix it? Replaced the "Drive Pulley"? Item # 22 on page 175 of the clymer 1986-1988. Figure titled Transmission. Fig #46 in chapter titled "Transmission and gear shift mechanism" So all I need to do is replace the "Drive Pulley" and the lock washer. I can reuse the old nut. It does not require any engine dismounting or rear whel dismounting. Just moving the rear wheel forward. As described in the "Drive Pully and Drive Belt" removal section of the chapter titled "Rear Suspension". Let me know if I am on the right track. Regards Autif |
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Title: Re: gear not engaging Post by za16866 on 09/17/04 at 06:15:28 you got it... thats all there is too it... just make sure that the shaft is smooooooth... when mine did it.. i got alot of metal shavings actually welded to the shaft..because the bushing on the hub is aluminum.. and so is the shaft... (dumb) but i didn't design it.... i just used a dremmel and took my time and removed any burrs that were there then hit it with some fine sandpaper to smooth it out good... let me know how you make out... glad to be of help... ;D |
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Title: Re: gear not engaging Post by tekxtc on 09/17/04 at 07:32:25 It is kinda rainy today evening and tomorrow. I will probably get to it on Sunday. I do not have a garage :-[ I will also have to order it thru one of the local suzuki dealers. It may be a full week before I can ride again :-[ http://www.weather.com/weather/local/01757?whatprefs= But its just a week ;D I will also take pics just in case. |
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Title: Re: gear not engaging Post by tekxtc on 09/17/04 at 09:31:39 How do I get the nut off the gear main shaft? because of the rust, the nut and shaft are rotating together. I have soaked them in WD-40. Will do soaks every few hours until sunday. Lets see where this takes us. Any other ideas? |
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Title: Re: gear not engaging Post by za16866 on 09/17/04 at 11:34:44 thats about the only thing i can suggest... or maybe us liquid wrench ... but... i believe that i needed to use a wrench and a hammer... sharp blows on the wrench helped it come loose... CAREFULLY!!! :o :o :o..... PATIENCE... but after that.. piece of cake.... |
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Title: Re: gear not engaging Post by Greg_650 on 09/18/04 at 07:06:46 tekxtc wrote:
Man, I'm really out of the loop on this topic. What hub? What shaft? What parts are made out of aluminum? Are we talking about the front pulley spinning on the output drive shaft? By the way, the hammer on the wrench will help to impact the nut loose from the pulley, but if it still wants to be stubborn, you can get a helper to hold the rear brake pedal down while loosening the nut. |
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Title: Re: gear not engaging Post by klx650sm2002 on 09/18/04 at 08:34:53 Won't work Greg the outer part of the front pully isn't attached to the middle. Clive W :D |
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Title: Re: gear not engaging Post by Greg_650 on 09/19/04 at 02:51:53 How the #%%#$@% does that happen? |
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Title: Re: gear not engaging Post by klx650sm2002 on 09/19/04 at 03:47:36 Probably wouldn't have happend with a chain drive. Clive W :D |
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Title: Re: gear not engaging Post by Greg_650 on 09/19/04 at 04:04:37 Need pictures, if possible. You're right. Wouldn't happen with a chain drive, but then we could look at pictures of pointy sprocket teeth instead :) |
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Title: Re: gear not engaging Post by tekxtc on 09/20/04 at 07:49:06 Will post the pics later today os so. Meanwhile here is the gist of things as they stand. 1) was able to get the nut (#38 in the pic below) from the main shaft (#15). Had to use 32 mm socket from Autozone and the wrench I had. Had to put the bike in 1st gear and it was not all that difficult after 2 days of WD40 + Liquid Wrench. 2) Will order the parts tomorrow as the dealer is closed Sunday and Monday :-[ 3) Will have pic of the old and new parts sometime today/tomorrow 4) The problem is that the internal teeth on the front pully (#35) that is supposed to mesh with the main shaft (#15) is all worn out. It is a circle instead of teeth there. http://houseofmotorcycles.bikebandit.com/partsbandit/showschematic.asp?dept_id=722603 I was wondering what may be the cause of this failure? I had just 9200 miles on my bike (all but the first 250 driven by me). Could it be because of ungaraged winter conditions of massachusetts, could it be the tight belt I had on for a few days (~400 miles). Could it be my hard riding habits? I always (almost always) do hard acceleration until the desired speed (35, 45, or 60) miles per hour is reached. Any other ideas? Will post pics of the older parts and then old and new together when they arrive.' Autif |
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Title: Re: gear not engaging Post by Diane on 09/20/04 at 09:15:42 I had a problem with the shifter feeling spongy. Took it in to be looked at about 2 weeks ago before going to a rally in New Mexico. The shift rod was bent. They straigtened it but had to order the part. So....... of course I'm in the middle of Nowhere, New Mexico when it bends again and I'm stuck in 4th gear. Lucky for me one of the guys with us knows how to work on motorcycles, he straightened it again and it just got me back to town. He went to a hardware store and for $4 bought some kind of metal tubing and a hacksaw, cut the tubing to size and got me back on the road again. Has anybody else had this problem? I feel that it should be repaired under my warranty but am betting the dealership wont agree. BTW.... If you've never been to Ruidoso NM I highly recomend it. |
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Title: Re: gear not engaging Post by Old Geezer on 09/20/04 at 13:57:33 Just got back from the rally in Ruidoso yesterday. My third one and my wife's first trip up on her Savage. We had a great time. Like you, I'd highly recommend making that rally or at least taking a ride up during the summer. |
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Title: Re: gear not engaging Post by Mr 650 on 09/20/04 at 23:38:42 Diane wrote:
Yeah mine was that way from day one. It was sorta mushy until it fatigued and broke. I took it to the shop and we welded it back together. I bought an 80's model shifter w/ linkage as a spare. |
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Title: Re: gear not engaging Post by Greg_650 on 09/21/04 at 02:35:46 tekxtc wrote:
Was the lock washer #39 bent over against a flat side on the nut #38? (before you removed it) I've had this pulley off a few times, and haven't had any troubles. Last winter I finally had to buy a new washer because the old one couldn't be used any more. But the splines on the shaft #15 (or the teeth on pulley #35) are gone? That sucks. |
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Title: Re: gear not engaging Post by za16866 on 09/21/04 at 06:26:17 i had the same problem with mine.. the teeth on the inside of the pulley were history.. and from what i got from the parts manufacturer.. there was a bunch of those pulleys that were made totally out of aluminum.. which in turn .. if the belt was too tight.. or just hard riding .. after time the shaft would take off the teeth.. when i recieved my new hub..there was a steel insert in the hub .. so...instead of the steel shaft and aluminum hub taking all of the pressure... it now is steel to steel... that way the teeth stay intact.....and the shaft doesn't as easily round out the inside of the hub....in my other post i had talked about using a dremmel... i used that to clean out all the grooves on the shaft to remove all of the remnants of the aluminum teeth... keep me posted... |
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Title: Re: gear not engaging Post by tekxtc on 10/06/04 at 09:56:08 After about a 20 day hiatus, I was able to ride again today. Replaced the front pulley. To answer Greg' question on 20th Sept: Yes, the lock washer was bent and had to flattened before it could be removed. I had a little bit of trouble bending the new one that was replaced with the pulley. Broke my rachetting screw driver:-( Also, the splines on the shaft are OK (slightly work out, but OK), but as you can see in the pic, the teeth on the pulley are all gone. http://www.angelfire.com/linux/autif/frontpulley.jpg Angelfire is blocking the image if you click on the link, but if you copy and paste the link, it will show! Good luck |
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Title: Re: gear not engaging Post by za16866 on 10/06/04 at 10:28:54 i can see that you had exactly the same problem... smoothed it out totally.. but i can also see that you got a hub with the steel insert too.. if you look at the hub on the right.. the hub is all aluminum.. the one on the left has an insert in it.. probably to stop that problem from happening again.. i'm glad you are back on the road.. happy riding....glad to be of help..... |
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Title: Re: gear not engaging Post by Greg_650 on 10/07/04 at 02:44:20 tekxtc wrote:
The link worked just fine. Much better than that pulley. Mine, I believe is steel but I'll check this winter. We learn something everyday. That bowl of mixed nuts looks good too ::) |
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