Transmission issues please help me gs gods!

[jzfn13]

Yeah, that was my thoughts as well, i wouldn't mind having a parts bike anyhow. The only problem is these gs'es are VERY few and far between here in the southeast. I'll have to get really lucky, and if you haven't noticed, luck surely is not my thing... lol

[jzfn13]

Allright, I am back from Vegas with my new super lightweight wallet modification. Time to tear into this beast. I have been trying to get the primary drive bevel gear out of the trans to try to take a look before I yank the whole motor. I have all four bolts out form the drive shaft and of course all four bolts were its housing fits into the case. I however for the life of me cannot seem to get this thing to budge at all. I have even resorted to hammering at it with a flat screwdriver as a chisel. I knocked a few bits of the metal? gasket out but it still wont budge. Is there a trick to getting this sucker out of here? Hidden bolt or something? Or should i just keep whacking at it with caveman force?

[tom203]

By primary drive bevel gear, you mean the one that's driven off the trans output shaft (with shock spring attached)? Have you been to Alpha-Sports.com website to see diagram of this "secondary drive" ? Lots of fun parts make up this bevel gear set.

[waltfen]

My GS650 Katana had 2 oil drain bolts. Apparently the one in the sump does not drain all oil out so Suzuki had to fit a 2nd one.
If you check the fiche diagrams, you'll find that there are 2 drain bolts from engine number 122596.

[Killer2600]

Chiming in a little late in the game but the symptoms sound like a bent shift fork or otherwise shift malfunction in the trans. Other things (the sound of rocks) may be broken because of the shift malfunction. The wheel lock up, stalled engine, and optional "pow" upon shifting into a gear are sure tells. Basically whenever two different gear ratio's engage at the same time the trans locks ups and the forces of the engine and bike momentum trying to make the locked up trans shafts turn can cause things to break.

Sorry I can't help with the disassembly of the driveshaft from the trans other than recommending a look at a parts diagram for your bike or the service manual which is a good thing to have if you wrench on your own bike and even good to have if you don't as whoever works on it for you might find it extremely valuable.

[jzfn13]

Spent a few more hours pulling the clutch out to test the trans a bit further. I can not tell you how much i hate these JIS philips screws, or how much i appreciate an impact screwdriver... I am happy to say all of the friction material and plates in my clutch look great, no notches on the basket or anything. Unfortunately my transmission is not so great. I spun the primary drive by hand and in every gear it gets really stiff or locked up about every two turns. That leaves the question of if i pull this whole motor and take my chances on an ebay pull, or try to rebuild the trans in this one. I am fairly mechanically inclined. I have rebuilt a few motors in my time, but the prospect of a transmission scares me. Anyone have any idea the difficulty in ripping apart these transmissions? Is it truly a daunting task or am i just being a pansy?

[jzfn13]

o wow, after looking through some manuals i have to say, I think i am going to look for a whole new (used) engine.

[tom203]

o wow, after looking through some manuals i have to say, I think i am going to look for a whole new (used) engine.

Somone one said "discretion is the better part of valor" or maybe it was "you got to know when to walk away...etc." I hate transmission work and I think the 650 shafty would be a challenge- are parts available at a reasonable price? Yeah, I'd take my chances on a whole other engine assembly from a junkyard or ebay stripper- the shipping cost is the biggie here if you can't find it local.

[cruiser58]

I wouldn't want to assemble one of these trannys that was totally disassembled but just replacing the main and layshaft is the easiest part of the project, but I didn't disturb the shifter fork assembly and my old tranny just had a slipping primary bevel gear so I just reassembled going by my old tranny.

[koolaid_kid]

I replaced the entire transmission on my GPz in one day with the help of a local Suzuki expert. Removed the engine from the frame, inverted it on my bench, removed the secondary shaft, removed the lower case half, and there she was. Got a used tranny off fleaBay for $50-$75 bucks. Slapped her back together and she is still going strong.
I would expect a Suzi to be similar.

[tom203]

That's a great pic , shows the little "teeth" on second gear that slides to right to lock up mainshaft for fifth gear. Very ingenius on some guy's part!