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

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

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  

I will also take pics just in case.

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!!! .....  PATIENCE...  but after that..  piece of cake....

Won't work Greg the outer part of the front pully isn't attached to the middle.

Clive W  

Probably wouldn't have happend with a chain drive.

Clive W  

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_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

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.