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Message started by marinero on 07/17/21 at 13:08:39

Title: Strange gearbox noise and no clutch function
Post by marinero on 07/17/21 at 13:08:39

Guys pls help me,

My LS650 from 1995 has died today on the road :(
I have heard some strange noise from gearbox/clutch not sure, 20 km before this happens.

I made a short break next to the road and after few minutes I wanted to go ahed and suddenly when I got in the 1st gear bike is not able to go, and milling sound is coming from gear box!!

I check oil level almost daily, there is enough oil 15-50W Ester.

Please help me with your opinions. My Suzuki is half of me..... Hope this is not a gear box failure :(((

Title: Re: riding on highway , heard whirling sound and d
Post by badwolf on 07/17/21 at 14:04:19

First of all, you should have started a new thread, the mods will most likley do it for you.
So now, is the engine still running, or did it die, or not start?
How many miles? Have you looked at the chain tensioner?
If it is running, does it make any difference in sound or motion, when the clutch is in or out?
The engine has a LOT of parts and functions, the more info you can give the better we can GUESS what it is.

Title: Re: riding on highway , heard whirling sound and d
Post by marinero on 07/17/21 at 14:13:35

Thank you badwolf for your prompt reaction.

The bike is running without any problem and idle nice. During idle there is a strange sound of thicking metal. If I try to put it in 1st it goes with a hard sound. When I am leaving clutch it's starting to mill. It's the same with 2ng gear.

I was afraid to not destroy the gearbox, so I cut it off and towed it with a Service truck to home.

Didn't try to start it over again.

The belt is tightened and looking ok. There is no major oil leaking. The bike is cleaned almost daily. Today I put in a new air filter. Mileage 37.000 km.

Title: Re: riding on highway , heard whirling sound and d
Post by badwolf on 07/17/21 at 17:05:24

You will have to pull the clutch cover off (right side as you sit on it) To see what is wrong.
With 37,000 km on it you SHOULD have at least looked at the cam chain tensioner by now.
Do you do your own work on the bike? Are you comfortable opening up the bike and working on it yourself? Do you have a place to work on it, inside? Some guys have to park on the street and can't do much themselves.
To get the clutch cover off you will need to drain the oil and take off the footpeg and exaust. Then you NEED TO MAKE A PATTERN OUT OF CARDBOARD TO PUT THE BOLTS IN SO YOU DON'T MIX THEM UP, OR LOSE THEM!
As you can tell by now taking off the clutch cover is NOT a''first time I ever worked on anything'' job. How much experince do you have working on cars, and bikes? Where are you? There might be a member nearby that could help.
If you get it off, post a picture of the open side so we can look at it, a pic is worth a 1k words.

Title: Re: riding on highway , heard whirling sound and d
Post by LS650THUMPER on 07/17/21 at 18:58:33

sold mine for $100 , got outta the Thumper game for now,
looked like it needed a
valve cover,
cam,
piston,
and tensioner.
bottom seemed ok but who knows !! so it went to a new home
Adio's for now !!!
the best forum around, be safe everyone !!!
#NotTodayRona

Title: Re: riding on highway , heard whirling sound and d
Post by marinero on 07/18/21 at 01:19:37

4E4C5F415F5D454C445F2D0 wrote:

I do just a simple works on my bike by myself. Don't have a place to work on it, I Live in the old city centre, and park my bike in passage to be protected from rain.. Location Herceg Novi, Montenegro (near Croatia).

My mechanists is only available during weekends, so I will have to wait until next weekend cause he is fully booked now. :(

Additional info: 2 months before I have changed my tires, front and rear. After that guy in the workshop didn't level properly rear tire and the PULLEY was scratched pulley cover. After that I levered the rear tire, check the tension of the belt and have to remove the pulley cover because it was making a noise when the bike is rolling in neutral. Don't know if this can be connected with this problem...

Title: Re: riding on highway , heard whirling sound and d
Post by marinero on 07/18/21 at 01:22:56

1995

Title: Re: riding on highway , heard whirling sound and d
Post by marinero on 07/18/21 at 04:01:29

I have made a video. Hope it will help you to figure out...

https://www.youtube.com/watch?v=fLcd-YgLjc4

Title: Re: riding on highway , heard whirling sound and d
Post by Gary_in_NJ on 07/18/21 at 04:38:02

Sounds like the belt is slipping on the counter shaft pulley. Are the teeth on the belt rounded? Have you checked the slack on the belt?

Title: Re: riding on highway , heard whirling sound and d
Post by marinero on 07/18/21 at 04:41:48

Sound is coming while I am releasing the clutch. The belt is looking fine. When the clutch is pressed fully and I try to shift it in 1st this noise is coming...

Title: Re: riding on highway , heard whirling sound and d
Post by Gary_in_NJ on 07/18/21 at 05:22:32

Which side of the bike is the noise coming from? Check to see if the pulley is spinning as you try to engage the gear.

Title: Re: riding on highway , heard whirling sound and d
Post by verslagen1 on 07/18/21 at 05:35:26

check to see if the spindle is turning within the pulley.
a lot of times the splines on the pulley wear out.

Title: Re: riding on highway , heard whirling sound and d
Post by marinero on 07/18/21 at 05:40:15

I have tried to put it in the first gear while is shut down. And whit the clutch fully released I can move the bike forward and backward?!

Title: Re: riding on highway , heard whirling sound and d
Post by Gary_in_NJ on 07/18/21 at 06:59:09

Time to inspect the clutch basket.

Title: Re: riding on highway , heard whirling sound and d
Post by marinero on 07/18/21 at 07:02:23

2822262C272E2A237D7B7F4F0 wrote:

Time to inspect the clutch basket.

Thanks, Gary for your time.
I will try to find a mechanist tomorrow and will share with you guys what is going on.

Title: Re: Strange gearbox noise and no clutch function
Post by Dave on 07/19/21 at 04:04:42

It is evident there is a problem with either the clutch - or the drive pulley.

If you can't determine if the noise is coming from the right side of the engine (clutch) or the left side of the engine (drive pulley) - I would start by removing the left side pulley cover and inspecting the pulley. If you see a powdery dust or metal shavings that is a good indicator the pulley nut is loose and the splines are damaged. Put the bike in gear and push it forward and see if the pulley turns while the shaft stays motionless. If the pulley is clean and the shaft and pulley both turn together - then it is time to look at the clutch

Title: Re: riding on highway , heard whirling sound and d
Post by marinero on 07/31/21 at 07:06:45

2B382F2E313C3A38336C5D0 wrote:

check to see if the spindle is turning within the pulley.
a lot of times the splines on the pulley wear out.

Guys!

Finally I got an update from my mechanist. It is pulley which has been worn out vs splines.

I just order new one from Germany and now have to wait on DHL :)

Will send you pics if everything will be finished and ok.

THANK YOU ALL a lot!

Title: Re: Strange gearbox noise and no clutch function
Post by marinero on 08/12/21 at 02:50:42

Hi guys!
Finally Suzi is live again :) See pulley photos

Title: Re: Strange gearbox noise and no clutch function
Post by marinero on 08/12/21 at 02:51:30

Another