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No power to rear wheel. Not the hub splines. HELP

  • Thread starter Thread starter jchaplick21
  • Start date Start date
Best of Luck to you fellas. When you do find it, and in the course of what you are doing you will, please post a picture of the failure.
 
Jchap, let me know what trans bits you might need. I think i have almost a full trans from when i split the cases on my 650g to replace the 2nd gear driven 32 tooth gear
 
I (again) have to say how much I love the GS Forum. The plot twists.. the "usual suspects" coming to the rescue...

This thread is like reading a murder mystery !!! I can't wait to see how it ends !
 
Well, we split the engine and found the failure, you're not going to believe what it was. From what I can tell, there are no other occurrences of this happening. Im going to lt Joe explain it though, he can do a better job than me.
 
Found It!

Found It!

We finally found broken parts! Saturday we split the case to find a perfect transmission, crank and visible piston/cylinders. We pulled out the main shaft/output and spring cushion but still no bad parts. We removed the spring from the output shaft hoping to find spring pressure was holding a broken assembly together, nothing. At this part we are starting to second guess everything we have done. The only parts left on the output shaft are the inner tranny gear, the driven helical gear and the other cog part for the cushion assembly. None of which we could spin on their own. For $hits and giggles we took it to my house to press off the driven gear and cog. The cog is pressed into the driven gear then machine welded so these came off together. The output shaft was fine but we found a hairline crack inside the cog. About 1/4" from the weld the cog had sheared but the press fit held it all together until it was under load. So we pressed off the damaged part and the inside was destroyed. It looks like it was a material defect possibly made worse by factory weld. The layers of metal at the shear point were almost flakey looking and peeling away. Talk about a rewarding find though, we were minutes from parting out this bike. We will post pictures as soon as we can.
 
I'd like to see what's up as well. Great job! Now you need some parts.

cg
 
Well, here is what happened. If you look at the engine delow, my issue was located in the output shaft/shock cushion assembly that mates with the secondary drive gears on the end of the drive shaft. It's the spring unit on the lower right.
IMAG0611.jpg

What happened was somehow that gear sheared, and the spring tension kept it appearing normal. When trying to test everything visually and by hand, it seemed normal. It was only as a last ditch effort we finally found what was wrong. Keep in mind this gear should be one piece. This is what we found.
 
Wow that thing sheared internally. Crazy.
No offense, but at the start of this thread the little voice in my head was like "ah, this new guy probably has a mis adjusted clutch cable" or something like that. Haha (of course I don't know you at all . Lol
It was a lot of back and forth about try this, try that....it became more and more mysterious.
REALLY glad splitting your cases brought the answer.
Still have some work ahead of you but it's nice to know what that problem was!
Good luck man!
 
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Holycraposis!!!!!

Good luck to finding the part and putting it back together! Keep us posted.

cg
 
Hard to imagine a 650 doing that. Must have been a defective part to begin with. Go to a Suzuki dealer and ask for a warranty repair.;) Good find.
 
The new part came in the mail today. I'm debating pressing it apart just to make sure haha. Then it's just a matter of adjusting the two secondary drive gears together and checking with gear marking compound. Crazy though right? Now it's just time to put it all back together.

Anything I should do while everything is apart?
 
That is wild. Your persistence to find the source of the issue is commendable, Soldiers of the Wrench.

If you took the top apart I would do the valve seals and lightly hone the cylinders. Nothing but Suzuki base gaskets if your going there. Take your time mating the gears. Sounds like you'll be back on the street in no time.

Congratulations
 
Wow, i don't think I would have figured that one out. But man, that engine is clean on the inside
 
Great detective work! Probably a defective casting. My 650's shock absorber spring gizmo seems to be making a bit more noise at 51k miles, so I've been following this tale of woe with interest.
 
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