SuzukiSavage.com - Stuck Transmission After Rebuildish

Robees

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Stuck Transmission After Rebuildish
10/10/16 at 20:03:09

I have a 2000 savage that started spewing oil out of the top end. After I pulled my engine, replaced all seals and gaskets, adjusted valves, and put her all back together, I cannot get the drive pulley to move. I have checked the rear brake and it is free and clean. Since the engine sat for a bit without oil I thought the clutch was stuck. I pulled the clutch out inspected the seemingly flawless plates, cleaned them and put it all back together. The engine runs great and I can "shift" from neutral to a few gears, when I let the clutch out the engine is obviously under load and struggles but the rear wheel doesn't budge. I did not remove the transmission cover during the rebuild. Any ideas?

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stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2641 Auburn, AL Gender:	Re: Stuck Transmission After Rebuildish Reply #1 - 10/10/16 at 20:21:37 Does the rear wheel turn when the belt isn't on it? Could be as simple as a frozen rear brake...if you're lucky. Otherwise, you're looking at an engine issue which I know nothing about.
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Robees YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 4	Re: Stuck Transmission After Rebuildish Reply #2 - 10/10/16 at 20:24:03 Yes I checked the rear wheel and it is free and clear.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Stuck Transmission After Rebuildish Reply #3 - 10/10/16 at 20:28:56 I think it's great that it runs. The other part ain't so great. I'd be taking the cover off.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Stuck Transmission After Rebuildish Reply #4 - 10/10/16 at 20:35:18 I'd pull the plug, get it in the highest gear possible and try to rock it back and forth, hoping to get it rolling.
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batman

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Re: Stuck Transmission After Rebuildish
Reply #5 - 10/10/16 at 20:35:27

Need more info,what seals /gaskets were replaced, you probably just had the head plug leak and went way to far. You pulled the engine from the frame? You can only shift it to some gears? I'm thinking you might have the shift linkage placed wrong where it goes on the shaft into the side case the slit should be faceing straight down in neutral and you should be able to shift to all gears if you spin the rear wheel by hand. You also need to have your clutch adjusted right,does the rear wheel spin by hand in neutral?did you bathe the clutch plates in oil after cleaning ?If not the clutch isn't going to drive the anything.

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Robees YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 4	Re: Stuck Transmission After Rebuildish Reply #6 - 10/10/16 at 20:45:14 Yes it was most likely the plug and I went too far so I had to follow through. I pulled the cylinder off and replaced all the gaskets accordingly. I can shift into first, second, and maybe third. It's hard to tell. I soaked the clutch plates. The drive pulley is frozen.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Stuck Transmission After Rebuildish Reply #7 - 10/10/16 at 21:56:27 My guess would be something was floating around in there and got caught between the gears. take the starter out, sparky and rotate the engine backwards. hope it falls out.
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Armen

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Re: Stuck Transmission After Rebuildish
Reply #8 - 10/11/16 at 02:49:01

Pop off the clutch cover.
Remove the cutch plates.
Pop off the drive belt.
Put the bike in gear and see if you can shift through the gears. Try to spin the drive pulley to help shift. When you do, does the drive pulley still turn?
The whole gag here is to isolate where the problem is.
You didn't split the cases, right?

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Re: Stuck Transmission After Rebuildish
Reply #9 - 10/11/16 at 04:28:51

If you didn't split the cases, there shouldn't be anything wrong with the transmission.

Did you remove the belt pulley (I would imagine you did if you took the engine out of the frame). Grab the pulley, and see if it will rotate just a tiny bit in either direction - if it does, then the issue is not with the output/pulley shaft. If you get no movement at all - then you have something wrong with that shaft, and I would recommend removing (or loosening) the pulley nut and see if the shaft frees up.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Stuck Transmission After Rebuildish Reply #10 - 10/11/16 at 07:52:18 Since the engine sat for a bit without oil Have to be quite a while, in a bad place, for the transmission gears to grow together. You didn't drop a nut or washer in it, did you? Several options for you on the board, keep us up to speed.
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Stuck Transmission After Rebuildish Reply #11 - 10/13/16 at 19:20:09 Robee,how ,if you removed the drive pulley ,How did you reinstall it? On the bench or in the bike? Air/electic wrench/or socket braker bar? Did you have the trans in gear when torqueing the nut?
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