SuzukiSavage.com - 86 transmission

reondadomino Junior Member Offline Posts: 60 TN Gender:	86 transmission 04/14/11 at 09:43:09 Would an 86 model transmission work on a 95?
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28651 Tucson Az Gender:	Re: 86 transmission Reply #1 - 04/14/11 at 10:51:43 Maybe,... probably,... don't really know.... But,... Why?... ...
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: 86 transmission Reply #2 - 04/14/11 at 16:46:59 if you mean take the gears and put them in the case... NO if you mean take the bottom end and put the top end of a '95 on... YES
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reondadomino

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Re: 86 transmission
Reply #3 - 04/15/11 at 09:31:31

What had happened was... I bought a used Savage, p.o. told me he never had any major work done to it, just carbs, oil, etc., however, I just tried to replace the drive belt and the sprocket pulley wouldn't come off. When I finally got it off I found that the drive shaft splines had been chewed and rather than replacing the drive shaft, the sprocket pulley had been JB welded to it!

So now, I have to replace the drive shaft, possibly the pulley too, but I don't want to buy a brand new one unless I have to.

I've found several on eBay, but most are from the 80s models. I was hoping the fitment would be the same.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28651 Tucson Az Gender:	Re: 86 transmission Reply #4 - 04/15/11 at 10:15:29 I'd take it to a shop,.. and have them weld it in place... It'll last 'till your belt breaks,.. could be 100k miles... ...
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reondadomino Junior Member Offline Posts: 60 TN Gender:	Re: 86 transmission Reply #5 - 04/15/11 at 13:58:52 Weld the sprocket pulley to the output shaft?
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IN-S40

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Re: 86 transmission
Reply #6 - 04/15/11 at 14:08:15

Yep, weld them together. From what I understand it would be a pain to replace that shaft, pretty much a complete engine tear down. Since you rarely have to get into the transmision weld it on. I have done a little bit of welding and i bet 4 good size welds at 4 points around the shaft and it would hold and you could cut the welds later if you had to get in there...

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: 86 transmission Reply #7 - 04/15/11 at 14:50:00 Of course welding is an option, but was the JB weld holding well enough? Might be just put it back the way it was. And perhaps take a tip from OF and grease one side so it'll come off.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: 86 transmission Reply #8 - 04/16/11 at 07:03:58 Ill be danged if Id replace that shaft.
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reondadomino

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Re: 86 transmission
Reply #9 - 05/04/11 at 11:48:17

Well, I bought the bike with the hopes of turning into a sweet little bobber and then selling it, so I don't think welding is an option. Plus, if I weld the sprocket to the shaft I'll have to open the left crankcase any time I have to replace a drive belt. But, then again, the gaskets are way cheaper than the friggn shaft!

I've already torn the engine down and pulled the shaft now though. I bought the 86 transmission b/c the part #s for the shaft were the same, however, what I didn't know is that in 95, the Savage become a 5 spd tranny instead of the old 4 spd. Fail. So now I have an 86 transmission for sale if anyone wants it. I'll cut you a deal since I just need to get rid of it. PM me. I'll post it in the market place too.

It appears that the Boulevard output shaft (main) is the right fitment for my 95. Found an 07 entire transmission for less than what a new main shaft costs on eBay. I'll probably go that route again.

If anyone has any idea about fitment, please let me know! I've had this bad boy for 2 mths now and still haven't gotten to fully ride it! Sad

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BurnPgh Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1732	Re: 86 transmission Reply #10 - 05/04/11 at 14:25:09 good luck getting it back together. You really just went the wrong way around. Chances are the shaft splines were fine and it was the pulley that needed the jb weld. Jb can also be removed if heated enough or consistently exposed to oil/gasoline. A torch probably wouldve done it.
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reondadomino

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Re: 86 transmission
Reply #11 - 05/04/11 at 14:32:36

BurnPgh wrote on 05/04/11 at 14:25:09:

good luck getting it back together. You really just went the wrong way around. Chances are the shaft splines were fine and it was the pulley that needed the jb weld. Jb can also be removed if heated enough or consistently exposed to oil/gasoline. A torch probably wouldve done it.

Actually, I removed the pulley and that's how I knew the shaft needed to be replaced. The splines on the pulley are in good condition, the shaft's splines basically broke off in my hands.

The only way to replace the shaft is to take the engine apart.

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CalisOsin Senior Member Offline Rather die, than live down on my knees. Posts: 297 Orange County, Ca Gender:	Re: 86 transmission Reply #12 - 05/04/11 at 16:12:01 verslagen1 - is the reverse of that true? Could I put the top end of an '86 on the bottom end of a '95?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: 86 transmission Reply #13 - 05/04/11 at 16:18:09 CalisOsin wrote on 05/04/11 at 16:12:01: verslagen1 - is the reverse of that true? Could I put the top end of an '86 on the bottom end of a '95? Not 100% sure but I think all years fit.
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