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No drive connection, rattling from shaft side

  • Thread starter Thread starter jsonewald
  • Start date Start date
J

jsonewald

Guest
The last time I rode my '82 650GL it made a sudden, short, grinding kind of noise, and then coasted to a stop. The engine starts and runs fine, but there is a rattling sound that seems to be coming from the lower left side of the transmission/drive case. In any gear the bike can be rolled easily. The clutch action feels normal, and looking through the oil fill opening I can see the clutch mechanism moving when the lever is squeezed.

Any ideas of what this is, and what the probable repair is? I am experienced enough in general to consider cracking the case myself, but I don't want to start without some experienced advice on what I may be getting into.

Thanks
 
Two possible things come to mind: the rear driven spline (in the rear wheel) has stripped, or the secondary reduction bevel gear has sheared. The rear wheel is easiest to check so I'd do that first. Suzuki made some soft splines for a few years and they are prone to failure - updated service parts are readily available from a dealer part source. The bevel gear failure relates to the nut backing off. There is a tutorial on how to repair this yourself with minimal cost, although some machine work is required. http://members.dslextreme.com/users/storagecliff/images/bevel_gear_shaft_repair_zooks.pdf

Good luck and welcome to the GSR.
 
Greetings and Salutations!!

Greetings and Salutations!!

Hi Mr. jsonewald,

So you finally posted? Now I can give you the "mega-welcome". ;)

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Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Rebuild Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. Now let me roll out the welcome mat for you...

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Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike! :D

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff
 
jsonewald said:
The last time I rode my '82 650GL it made a sudden, short, grinding kind of noise, and then coasted to a stop. The engine starts and runs fine, but there is a rattling sound that seems to be coming from the lower left side of the transmission/drive case. In any gear the bike can be rolled easily. The clutch action feels normal, and looking through the oil fill opening I can see the clutch mechanism moving when the lever is squeezed.

Any ideas of what this is, and what the probable repair is? I am experienced enough in general to consider cracking the case myself, but I don't want to start without some experienced advice on what I may be getting into.

Thanks
Click to expand...
What's the mileage/ history and are you prone to blazing starts?
 
tom203 said:
What's the mileage/ history and are you prone to blazing starts?
Click to expand...

I bought the bike < 2 years ago with 26K+ on it, and have since put ~8K on it. I'm not prone to blazing starts. However, this area of east TN has some seriously twisty and hilly rides (Dragon's Tail, Devil's Triangle). I have ridden both, and many times for the Triangle. It is pretty demanding of the drive train.
 
jsonewald said:
I bought the bike < 2 years ago with 26K+ on it, and have since put ~8K on it. I'm not prone to blazing starts. However, this area of east TN has some seriously twisty and hilly rides (Dragon's Tail, Devil's Triangle). I have ridden both, and many times for the Triangle. It is pretty demanding of the drive train.
Click to expand...
You'll have to put bike on centerstand, put in gear (NOT RUNNING ) and wiggle rear wheel back and forth. Any clunking? Where? Pull back rubber boot at front of driveshaft and investigate. No sense looking for replacement parts till you know what's wrong. This drivetrain is overdesigned for this bike ( properly lubricated), no matter how twisty and fun the roads are.
 
tom203 said:
You'll have to put bike on centerstand, put in gear (NOT RUNNING ) and wiggle rear wheel back and forth. Any clunking? Where? Pull back rubber boot at front of driveshaft and investigate. No sense looking for replacement parts till you know what's wrong. This drivetrain is overdesigned for this bike ( properly lubricated), no matter how twisty and fun the roads are.
Click to expand...

Thanks for the advice. This is much better to start with, instead of opening the case.
 
I am having the same trouble. I have experianced this kind of "ka-chunk" before but she has slipped back into a gear quickly. This time it stayed stuck between 3rd and 4th gear. I had to send my riding friends after the truck. I brought it home thinking the cases would have to be split and stuff replaced. I was excited because I have had the intentions of hard-tailing the frame and going Very custom. Now the frame is stripped and ready to be welded up and powder coated, and I have been toying and avoiding the engine breakdown. I have tinkered with it to breakdown the possibilities of what it could be closely following the factory service manual and the suggestions in the forum. It is not the diff, or the bevel gear. Now that the engine is out of frame and halfway torn down I have noticed that the gears shift through without an issue and there is no longer zero resistance in the bevel gear output.... wtf Did the Zuki just heal or am I losing it? Lord... if you listinin.... HELP!!
 
Breezy said:
I am having the same trouble. I have experianced this kind of "ka-chunk" before but she has slipped back into a gear quickly. This time it stayed stuck between 3rd and 4th gear. I had to send my riding friends after the truck. I brought it home thinking the cases would have to be split and stuff replaced. I was excited because I have had the intentions of hard-tailing the frame and going Very custom. Now the frame is stripped and ready to be welded up and powder coated, and I have been toying and avoiding the engine breakdown. I have tinkered with it to breakdown the possibilities of what it could be closely following the factory service manual and the suggestions in the forum. It is not the diff, or the bevel gear. Now that the engine is out of frame and halfway torn down I have noticed that the gears shift through without an issue and there is no longer zero resistance in the bevel gear output.... wtf Did the Zuki just heal or am I losing it? Lord... if you listinin.... HELP!!
Click to expand...
Praying might help, but slipping out of gears, and then staying stuck between them is trouble. Out of frame, there's little load on gears, so you'd get a false impression of what's going to happen when the gears are loaded. I haven't openned one of these up yet, but others will probably steer you in right direction.
 
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