SuzukiSavage.com - gear not engaging

Mr 650

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The LS650- Classic
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Re: gear not engaging
Reply #15 - 09/20/04 at 23:38:42

Diane wrote on 12/31/69 at 16:00:09:

I had a problem with the shifter feeling spongy...
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.

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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SilverBlue '01,K&N,Snorklectomy,125mm NOS carb, 1/2 spacer & 155, 'Trapp, NC flyscreen, Suzy GelSeat, Osram H4
later..putt. Putt, PUtt, PUTT! 8)
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Savage_Greg

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Don't go around your
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Re: gear not engaging
Reply #16 - 09/21/04 at 02:35:46

tekxtc wrote on 12/31/69 at 16:00:09:

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 Embarrassed

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_i...

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

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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za16866

Ex Member

Re: gear not engaging
Reply #17 - 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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tekxtc

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Re: gear not engaging
Reply #18 - 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 Sad

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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za16866

Ex Member

Re: gear not engaging
Reply #19 - 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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Savage_Greg

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Re: gear not engaging
Reply #20 - 10/07/04 at 02:44:20

tekxtc wrote on 12/31/69 at 16:00:10:

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 Sad

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

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 Roll Eyes

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