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Counter shaft problem update with pics, now what is this?

  • Thread starter Thread starter rombi
  • Start date Start date
R

rombi

Guest
O.K. so I folowed some great advice and convinced my cover that it needed to come off the bike. The gear shifting problem might be worse than I thought. What do you think, can I fix the kink????
 
never mind the grease:)

Do you think this can be fixed to make her shift somewhat normal again?
 
short of replacing the shifter rod, i'd guess the answer is: no, you cant straighten that kink (and in the process of trying you may do further damage) :(
 
Hi Mr. rombi,

That thing is crookeder than Bill's Clinton. :eek:

I think replacement may be your only option. Sorry.


Thank you for your indulgence,

BassCliff
 
i wouldnt even try to fix that SOB, and im drunk as a mofo right niw
 
What model bike are we talking about. You will not need to split the cases to replace the shaft. Just remove the clutch and shifting mechanism from clutch side of cases.
 
Its easy to replace BUT you need to get the dremmel out & cut the shaft off before you remove it
 
Anyone have a step by step way of getting that out. I thought I was going to have to split this open to fix, sounds like I can get it out easier. I don't want to do further damage or make it more costly.
 
We need to know what year and model bike to give you a step by step.
 
Sorry, it is a 82 GS650E. It has about 23,000 miles on it.
I have had a ton of bikes over the years. All sportbikes and all very fast. There is something about this old GS that is more fun and I am more willing to put up with a few "projects" like this to drive it. I see guys pulling wheelies and I still feel like I want a sportbike at times. I think I am getting older and smarter. Took a long time.
 
As Lynn said, get a dremmel tool with cut off wheel and cut the shaft off as close to the case as possible. Now remove the clutch cover on the other side of the bike. Once you get the cover off you need to remove the six screws holding the clutch plates and springs. Last thing is to get the large nut off the clutch hub. An air driven impact gun helps or you are going to have to figure a way to hold the clutch hub while the nut is removed. After you get the nut off, the clutch hub will pull free and you can get at the shaft from that side and pull it through and out.

Good luck.
 
Isn't the gears attached to this shaft? This doesn't sound like a quick job. Does anyone have a schematic of this? I appreciate the help, just want to get as much info as possible before I open this can of worms up.
 
rombi said:
Isn't the gears attached to this shaft? This doesn't sound like a quick job. Does anyone have a schematic of this? I appreciate the help, just want to get as much info as possible before I open this can of worms up.
Click to expand...

You can look up the schematic yourself by going to bikebandit.com and looking at the parts manual.
 
Cool just got the schematics. Trying to figure out how that is going work.
 
1/ Drop the oil from the sump.
2/ Brake pedal and right side foot peg off.
3/ Clutch cover off (get a new gasket to rebuild it)
4/ Remove the 6 retaining bolts of the inner clutch and remove the cover.
5/ Remove all the clutch plates.
6/ Knock the tab washer down (you will need a new one) that holds the inner and outer clutch basket in place.
7/ Undo the main clutch retaining bolt on.
8/ Remove the clutch baskets.
9/ Remove the gear change shaft and replace with straight one.
10/Work in reverse and rebuild it.
11/ Job sorted have a beer/cigarrette or go for a blast.

If you were in the UK and close I'd do it for fun. About 3 hours with a couple of tea breaks.

Suzuki mad.
 
11/ Job sorted have a beer/cigarrette or go for a blast
I will start with that first. Seriuosly thanks for the information, I would buy you a pint and smoke a fag with you mate if you were close.
 
If you have any air tools at home or where you are working once you get to the clutch nut you jam rags inbetween the clutch inner and outer basket so that the two lock. Then using an impact gun and socket remove the nut. Easy way to do it. Just watch the washers and positon of the baskets to the shaft and colar behind when it comes apart.

Here's what you should get to, or something similar.

Suzuki mad
 
Last edited:
now that is a good pic. I might be able to do this. that shift rod is $50 new
 
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