1986 GS750es (Canadian??) 2nd Gear Slipping

[Anonymous]

Hello everybody... this is my first post to the GSResources, so go easy on me
I bought an '86 GS750es from a guy in town here, and because it was my first bike, I didn't know that the second gear was having problems.
I did not get to test drive it, and otherwise it looked in excellent shape.
So basicly from what a few locals here in Ottawa, Ontario, Canada have said is that either the 2nd gear is physicly damaged / chipped / missing teeth, or perhaps the dogs are worn on the 2nd gear, and the one it mates with as well.

Has anybody else had this problem with their GS?
also, any ideas why this particular model is so damn hard to find a manual for? Is there any chance anybody would have a haynes / clymer / OEM Service manual for it?

here's a picture of it for anybody that can help me out... (I got a LOT of work ahead of me considering I've never torn apart a transmission before)

http://members.rogers.com/ronnygant/images/86%20Suzuki%20GS750%20ES.jpg

P.S. - could this be done without removing the engine?

Thanks SOOOOOOOOOOO much !!!!

Dave

[Anonymous]

Good to see another Ottawa GS Rider! Check the forums, i've got a couple problems on the go.

I can't really offer you too much insight, since my GS is my first bike too, but if you need a hand or whatever, don't hesitate.

Who did you end up calling?

[Anonymous]

There are a couple routes you could go. If you want to fix it you can take the part down to cycle salvage or email motorbiketoronto.com for the parts. Fixing the bike will include a complete engine teardown so you'll need a gasket set (possibly rings if you are clumsy) and the transmission parts. For under 600 dollars you may be able to buy an engine (1100 or 1150 possibly but ask around to see if they swap for later models) and put it in over a day or two. That will be the best thing to do if you are ready to ride. You should ask the guy you bought it from how long it has been giving him trouble. My 400 pops out of second if I hammer the gas hard but it otherwise rideable.

Steve

[SqDancerLynn1]

Not what you want to hear but the Cheepest way to repair would probably be to find a good used 750 engine, putting an 1100 motor would be a great preformance mod but they are getting hard to find and expensive. To repair the trans I would get the factory manual if you can find one. Do a search for Robert Sheldon?? in the forum he has a lot of manuals available

[Anonymous]

About the enginechange ideas, I think it will be a VERY tight fit to have a 1100 engine in that bike unless you mean a GSXR 1100 engine. I was about to do it to my 750 but when I measured the frame I got uncertain of the possibilities to fit it in so I gave up the idea.

About the second gear, that is quite a common problem in bike gearboxes. I had it on my 750 too. I took apart the whole engine and inspected the dogs on the sprockets. My gear slipped only at high load after 8000rpm. I went for undercutting both second and third gear since the dogs were not too damaged. Gave me a feeling of a new gearbox, very nice -and cheap too. But if the dogs are too worn you might have to replace the 2 sprockets. If so, go for undercutting them right away, I promise you wont regret it. And while youre at it; check the other sprockets teeths for pitting-injuries. Very common if the engine has been using a cheap engine-oil. Then you should replace them too. Remember that the second drive gear is pressed onto the shaft with strong threadlock compound. Very important to measure the distance from the shafts end to the sprocket. My advice is to have it welded by a TIG-welder once it is back in place. Just a precaution just in case of slip.

[Anonymous]

Nice looking bike Dave - and good luck with the tranny problem. hope to see you around town sometime.