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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Transmission assembly problem /cgi-bin/YaBB.pl?num=1367529381 Message started by Andreas on 05/02/13 at 14:16:01 |
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Title: Transmission assembly problem Post by Andreas on 05/02/13 at 14:16:01 Hi guys, a few days ago I got (not bought) a '93 Savage from a friend which was completely stripped down. The engine was completely opened, but all the parts were available. After some major cleaning, I've started assembling the engine. My problem is regarding the transmission gears assembly. To be honest I spent a lot of time reading the Clymer's manual even searching the net regarding the assembly of the transmission, with no luck. My first observation is that the counter shaft's diameter is 25mm while the bearing's diameter on the right crankcase half is 22mm! I've also read that '93 models are equipped with a 5-gear transmission (instead of 4-gear on earlier versions). Can you please give me some tips on how to reassemble the transmission? Why the bearing is smaller than the shaft??? :o I've attached some pictures showing the parts I've described for your convenience. Regards, Andreas |
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Title: Re: Transmission assembly problem Post by verslagen1 on 05/02/13 at 15:33:37 I'm thinking the 5speeds didn't start til '95 when they were re-introduced to the US. Where are you? Only a very few have torn down that far, keep posting and hope those few will chime in. (wow, you can attach that now?) |
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Title: Re: Transmission assembly problem Post by Andreas on 05/02/13 at 22:25:41 Maybe you are right. But comparing the shaft bearings with the pictures in the manuals and the web, I am pretty sure that this has to do with a 5speed model. I am a non US. Actually I am from Cyprus. A small island in the eastern meditteranean sea. Any ideas regarding the bearing and shaft diameters? |
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Title: Re: Transmission assembly problem Post by verslagen1 on 05/02/13 at 23:00:58 Maybe this will be of some help to you... http://i600.photobucket.com/albums/tt82/serowbot/Savage%20Exploded%20Views/ls650-parts-list_69_zpse3d96537.jpg |
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Title: Re: Transmission assembly problem Post by Serowbot on 05/02/13 at 23:11:40 If.... ...no,... ...when, you figure this out... You can be our resident tranny expert... ;)... I went down there once,... and got a washer mixed up... ...(okay,... I went down there,... twice)... :-[... I don't like it down there... :-?... |
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Title: Re: Transmission assembly problem Post by Andreas on 05/02/13 at 23:22:33 Thanks for the replies guys! I've got that manual and I was watching ir it for several hours trying to figure out what is going on... The problem is that I got the bike completely stripped down. I wasn't the one opening the engine. That's why I am struggling to put togerher the transmission. Everything else seems pretty straight forward. Anyway, I ll keep trying untill I do it! P.S: I dont like it down therr either... :( |
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Title: Re: Transmission assembly problem Post by Serowbot on 05/02/13 at 23:39:07 Is this any help?... It's from the Savage Companion disc... Downloadable in the Tech section... http://i600.photobucket.com/albums/tt82/serowbot/Transmission_Shafts_zpsba7d34a7.jpg |
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Title: Re: Transmission assembly problem Post by Andreas on 05/03/13 at 04:22:49 Thanks Serowbot. I've already downloaded the Savage companion disc (very good job by the way!!!). I don't know the year of this savage posted here, but the transmission is different than mine. It seems older than '93 model (you can see the differences on pic3 I've posted before). I am also attaching two new images with the gears removed and labeled as per manual. I am really confused now. How come and the main shaft has 4 gears and the counter shaft has 5??? I might try to contact the nice gentleman who made the savage companion disk. He seems that he went that far de-assembling the whole transmission... |
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Title: Re: Transmission assembly problem Post by Andreas on 05/03/13 at 21:41:00 Does anybody else believe that my countershaft is not suitable for my bike? As I said before, the engine was completely stripped down when I got it. Maybe they gave me the wrong countershaft... >:( |
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Title: Re: Transmission assembly problem Post by verslagen1 on 05/03/13 at 21:52:47 I've added andy's pic's |
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Title: Re: Transmission assembly problem Post by verslagen1 on 05/03/13 at 21:53:13 one more |
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Title: Re: Transmission assembly problem Post by verslagen1 on 05/03/13 at 21:58:55 this looks wrong. you got 4 gears on top and 6 gears on the bottom. 'bots has 5 and 5. and the clutch shaft has too many splines. does the clutch fit on there? |
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Title: Re: Transmission assembly problem Post by Andreas on 05/03/13 at 23:05:42 That's it verslagen!!! It doesn't fit and now I am absolutely sure that the guy gave the wrong countershaft. Maybe from a different bike. As soon as I get the right I will let you know about my work. I might add some pictures 8-) Thanks |
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Title: Re: Transmission assembly problem Post by wambr on 05/03/13 at 23:10:33 I beg your pardon, but i can't give you good advice... I wasn't even the transmission of the Savage, but it seems to me some gear on the countershaft "not here".... the photos can only say that on the countershaft average gear(which with the stubborn fingers on both sides) is most likely set to "someone" from other transmission... gear, which is right in my opinion at all with 4 gears transmission . is just some assorted... :( |
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Title: Re: Transmission assembly problem Post by SALB on 05/04/13 at 09:29:38 Looks to me as if some of the gears were mixed and put on the wrong shafts. :-/ :( |
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Title: Re: Transmission assembly problem Post by Andreas on 05/04/13 at 11:29:09 7B787B6F79717F1A0 wrote:
No... I am convinced that I have a completely wrong counter shaft. I've already asked for the right one and I believe that I'll have it in about ten days. I 'll let you know how it goes!!! |
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Title: Re: Transmission assembly problem Post by justin_o_guy2 on 05/05/13 at 09:00:51 Ive never wanted anything to do with the puzzle they call a motorcycle transmission. I cant imagine wading off into one someone else dumped out of the box. I sure dont envy you, but I will follow along & cheer for you when you win it, & someones done gone & slipped a piece in from another puzzle? Thats just wrong right there,, |
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Title: Re: Transmission assembly problem Post by 87 savage on 05/05/13 at 15:54:18 43414441581A19280 wrote:
Andreas, The countershaft is the same diameter on the 4 speed and the 5 speed. I just did an engine split last month due to a crack in the right crankcase half of an 98 5 speed engine that I swapped into my 87. I split both engines and put my right side crankcase half from the 87 on the 98. They are Identical. The bike is up and running with no leaks and shifts fine. The countershaft diameter IS 22mm on the clutch side. |
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Title: Re: Transmission assembly problem Post by Andreas on 06/17/13 at 09:31:21 I want to thank all of you for your precious help! I bought from ebay a complete used transmission assembly from an '87 Savage. I've installed it and now is shifting gears like a charm!!! ;D ;D ;D |
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Title: Re: Transmission assembly problem Post by justin_o_guy2 on 06/18/13 at 07:33:38 cheater! |
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Title: Re: Transmission assembly problem Post by Dane Allen on 06/18/13 at 13:41:18 7C6365627F7849794971636F24160 wrote:
;D ;D ;D Dude, that is way too funny!! Seriously, though, he is up and riding and that is the best place to be!! |
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