SuzukiSavage.com - Transmission assembly problem

Andreas

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Transmission assembly problem
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??? Shocked

I've attached some pictures showing the parts I've described for your convenience.

Regards,
Andreas

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pics.zip

Currently on two wheels... I lost the other two of my car!

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: Transmission assembly problem Reply #1 - 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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Andreas YaBB Newbies Offline Badass Posts: 42	Re: Transmission assembly problem Reply #2 - 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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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: Transmission assembly problem Reply #3 - 05/02/13 at 23:00:58 Maybe this will be of some help to you...
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28672 Tucson Az Gender:	Re: Transmission assembly problem Reply #4 - 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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Andreas

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Re: Transmission assembly problem
Reply #5 - 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... Sad

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« Last Edit: 05/03/13 at 21:51:11 by verslagen1 »

Currently on two wheels... I lost the other two of my car!

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28672 Tucson Az Gender:	Re: Transmission assembly problem Reply #6 - 05/02/13 at 23:39:07 Is this any help?... It's from the Savage Companion disc... Downloadable in the Tech section...
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Andreas

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Re: Transmission assembly problem
Reply #7 - 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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gears.zip

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Andreas YaBB Newbies Offline Badass Posts: 42	Re: Transmission assembly problem Reply #8 - 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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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: Transmission assembly problem Reply #9 - 05/03/13 at 21:52:47 I've added andy's pic's
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: Transmission assembly problem Reply #10 - 05/03/13 at 21:53:13 one more
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: Transmission assembly problem Reply #11 - 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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Andreas YaBB Newbies Offline Badass Posts: 42	Re: Transmission assembly problem Reply #12 - 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 Thanks
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wambr

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Re: Transmission assembly problem
Reply #13 - 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... Sad

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SALB Serious Thumper Offline FSO Posts: 668 Whittier, AK Gender:	Re: Transmission assembly problem Reply #14 - 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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