serious issue with drivetrain - 2nf gear locks rear tire!

[tfb]

CAREFUL, there, Suzuki Mad.

You have to remember that he's on this side of the Pond. If he uses a "torch", he's likely to burn the place down.
Over here, we call that thing a "flashlight".

A "torch" is also known as "a blue-tipped wrench". It is occasionally used to remove "frozen" bolts and nuts.

[whiteboyslo]

that's ok. whenever i read Suzuki mad's posts, i just have Eddie Izzard's voice going through my head and somehow i get all the little American English to English English nuances.

Mike

[Suzuki mad]

The cheek.......

that's ok. whenever i read Suzuki mad's posts, i just have Eddie Izzard's voice going through my head and somehow i get all the little American English to English English nuances.

Mike

Eddie Izz 'bats for the other side' thank you very much.

If you want a sound a lookalike model try a mixture of Luciano Pavoroti but talking like Bob Hoskins (The guy from Who Framed Roger Rabbitt.)

OK, fun over...............So, how do 'we' help this guy get his bike problem identified and fixed....

Suzuki mad.

[whiteboyslo]

well, it'd help if i got off my butt and did something with the bike.

i went out last night and started her up, because Lord knows i don't want to take more steps back. even with the clutch in, it wasn't disengaged in the lower gears (1st, 2nd, and even Neutral). however, once i shifted her up past that, i could get the clutch to diengage everything and fire her up.

if i have time this weekend, i'll at least pull the clutch and see what i can see. i picked up a used clutch set (incl a new basket) from ebay, mainly to try and get rid of the infamous clutch rattle. it may be next weekend, though. i've been putting off the front brakes on my truck and they sorely need done.

Mike

[whiteboyslo]

ok, so i went out and started the bike again today...

found something interesting. in first, neutral, and what i THINK is 2nd, i can idle the bike with the clutch completely out. upper gears, if i let out the clutch, it stalls like you'd expect.

any clues?

Mike

[Suzuki mad]

Sounds like 2nd is moving on the input shaft, (counter shaft as per suzuki.)

The cog is pushed on to the shaft with about 25 tonnes of pressure and a little 'loc tight.' If its moving its a new shaft.

Its an easy job to do. Split the cases, shaft out. Using a puller and press on the 5TH GEAR draw the two cogs off the shaft. All the others are held on with circlips. Replace the shaft and all the bearings and circlips the have the cog pushed back on to the new shaft. Refit, cases to gether. Job done.

Suzuki mad.

[whiteboyslo]

i've seen used gearsets on ebay for about $50 USD. would you recommend replcing the gearset with an entire used set, or.....?


Mike

[Suzuki mad]

If you can get a good 2nd hand one great. Just change the bearings on the end of the shafts and all the seals.

If your cogs are in good nick the cheapest way would be to get the cog welded to the shaft. The shaft and cogs would then be permantley fixed and if you had a problem later it would be useless to repair but would do the job.

If you can afford it I would go for a new shaft and replace all the bearings. That way you have vurtually a new gearbox.

That is summizing that 2nd is rotating on the shaft.

Suzuki mad