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Tranny/Shifting problem

Aside from 1st gear, it feels like nothings there.

Everything is on the low to mid end, but all within spec.

Will attempt to hand shift, but plan on pulling the clutch hub and check the shift fork.

My computer is down. Have to use my fathers, which is a pain in the a--!Will post the results soon-ly. Maybe pictures if needed. Thasnks for all the suggestions and help.

Andy
 
OK, I fianlly got a chance to pull the whole clutch assembly. I think I solved the problem, but would like some input before I re-assemble the whole thing.

1st off, after pulling the clutch assy, everything looked ok. I looked in the manual and tried to compare pictures of the inner workings and noticed my shifting fork was in the wrong position(off by 1 or 2 teeth) I then removed the shift lever and slid the shaft to the right side of the bike and repositioned the shifting fork up 1 or 2 teeth and re-engaged it with the little dog it meshes with and slid the shaft back to the left, the reinstalled the sfift lever. I then turned on the key and was able to shift thru all the gears(having to move the rear wheel a little).

Does this sound like problem solved? I would like any input before re-assembly and trial.

Thanks,

Andy

P.S. no pictures, I think this was the problem and didn't feel the need. I could still take some if needed. Just ask.
 
From not being there I would say give it a shot!
Hope it is that easy :D
 
indeed, sounds like a problem solved

that dog can be a dog to put in the right place (pun intended)
i played with it for a while when i had the engine disasembled on the bench, before i was confident i was putting it back the correct way
 
Well, every thing is back together. I also swaped the carbs for a better set. No fine tuning has been done yet, but she is running real smooth:).

The problem still remains. I can shift thru all gears without problem. I still however, release the clutch without the bike lurching and stalling. I also cannot start it in gear with the clutch lever depressed. I have tried to adjust the cable, with no success. Not sure what to do next. The only thought I have is the clutch plate and fiber behind the piano wire keeper my be stuck. I didn't pull these when I had the clutch apart. The manual recomends to replace the wire each time you remove it and I didn't want to order just that part and have to waite for it.

Anybody have any ideas??

Andy
 
Take off the clutch cover. Take out the fibers and steels. With the bike in neutral the middle clutch hub should turn easily. If not you pinched the bearings or installed it wrong.
Hope this helps
 
so, when on the centrestand and the engine running, you pull the clutch in and shift into 1st gear - and with the clutch pulled in the wheel keeps spinning?
unless you instaled something incorrectly at the clutch assembly or are missing some parts i would suspect the clutch cable
(or the clutch actuating rod and/or lever being positioned incorrectly)
 
With the steels & fibers removed the inner hub spins like a top! I can't be 100% sure, due to the fact that I never pulled the clutch apart before, but the whole assembly went back together as it was taken apart. No parts bound up or were forced back into position. The whole process seemed quite easy and I did follw the pictures in the Suzuki manual.
I have read several post that talk about weak clutch springs. Could mine be to strong or over torqued? I did measure them while I had them out and they were within spec, on the low end. Im pretty sure this is going to be a simple matter to fix. Probably is the cable or actuator arm mis-aligned. It is real frustrating. I have tried to adjust the clutch cable from one extreme to the other looking for the sweet spot or at least something a little better to let know Im heading in the right direction, without success. All tips and suggestions are welcome and appreciated, thanks.

Andy
 
ALB80-850 said:
With the steels & fibers removed the inner hub spins like a top! I can't be 100% sure, due to the fact that I never pulled the clutch apart before, but the whole assembly went back together as it was taken apart. No parts bound up or were forced back into position. The whole process seemed quite easy and I did follw the pictures in the Suzuki manual.
I have read several post that talk about weak clutch springs. Could mine be to strong or over torqued? I did measure them while I had them out and they were within spec, on the low end. Im pretty sure this is going to be a simple matter to fix. Probably is the cable or actuator arm mis-aligned. It is real frustrating. I have tried to adjust the clutch cable from one extreme to the other looking for the sweet spot or at least something a little better to let know Im heading in the right direction, without success. All tips and suggestions are welcome and appreciated, thanks.

Andy
Click to expand...

Andy, you have a pic of your actuator arm and what not assembled? Id like to see it. Sometimes you have to cock that arm back around from where it was. I seem to remember mine being in a little different position than it is now before the springs were changed in my 1100G.
 
TCK-

Right now everything is assembled. If I have to take it apart again Iwill get some pictures. If it will help I can take some pictures of it as it is now, maybe you can tell if the arm is misplace from that. I did compare the position to the position of an arm on a 650L(my next project) and they appear to be real close or the same. Thanks.

Andy
 
ALB80-850 said:
TCK-

Right now everything is assembled. If I have to take it apart again Iwill get some pictures. If it will help I can take some pictures of it as it is now, maybe you can tell if the arm is misplace from that. I did compare the position to the position of an arm on a 650L(my next project) and they appear to be real close or the same. Thanks.

Andy
Click to expand...
No no, im sorry, I meant i would like to see a pic of the arm and what not, assembled. Not not assembled... not that i wouldnt want to see that too.. just not is not what im looking for. Not that it matters...LOL

Yeah a pic of it put together would be great...

TCK
 
ALB80-850 said:
I have read several post that talk about weak clutch springs. Could mine be to strong or over torqued?
Click to expand...

no
it is the distance (travel) of the clutch lever mechanism that matters when separating the clutch plates
springs only make the plates' engagement pressure harder or softer
 
DSC01484.jpg


Here is my shift arm lever position. Sorry for the delay, photbucket and I do not play well.

Andy
 
That clutch arm is significantly inboard of the one on my 850. I'd loosen the cable all the way and remove the arm, then reinstall the arm as far outboard as possible. Clutch cable should have a small amount of play and that's it.

Good luck.
 
Last edited:
Nessism said:
That clutch arm is significantly inboard of the one on my 850. I'd loosen the cable all the way and remove the arm, then reinstall the arm as far outboard as possible. Clutch cable should have a small amount of play and that's it.

Good luck.
Click to expand...
Yeah I have to agree with Ed here, i think that is your problem. Mine on my 1100G, which might as well be the same motor, sticks WAY out there...give it a shot.
 
Will give that a try. Am going to remove the clutch assembly and take pictures of the shifting fork and internals to post and get your opinions. Im thinking the shift fork might still be off by a notch or 2. I think the problem is real close to being solved(at least I hope so).Thanks for all help.

Andy
 
I would love to get this thing down the road today. It would be a real nice b-day present to myself:):)
 
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