Stuck in 4th & 5th

[allojohn]

Posted this is General Maintenance, moving it here.
Original thread.

Things took a major turn for the worse today. Now I can only get 4th & 5th gears.

I did some reading through old posts and will remove the clutch basket hoping to find a problem with the change paw bits.

Feel free to chime in with suggestions.....

 

[koolaid_kid]

I am afraid I also would suspect a bent shifter fork.
I replaced my transmission in my GPz by removing the engine, flipping it upside down and splitting the cases. Since I have read the engines are very similar, you may be able to do the same thing. Picked up the entire transmission off fleabay for cheap, took 2 days with help from a friend who is an excellent mechanic.
Of course, I had so much practice removing and installing the engine it was a piece of cake.
ebay example

 

[allojohn]

I am afraid I also would suspect a bent shifter fork.
I replaced my transmission in my GPz by removing the engine, flipping it upside down and splitting the cases. Since I have read the engines are very similar, you may be able to do the same thing. Picked up the entire transmission off fleabay for cheap, took 2 days with help from a friend who is an excellent mechanic.
Of course, I had so much practice removing and installing the engine it was a piece of cake.
ebay example

Doh! here's hoping it isn't a bent fork. BTW the forks look as if they are cast alloy, if they are how can they bend?

 

[hampshirehog]

Definitely worth pulling off the clutch and having a look there before splitting the engine further. You might just have some gunk in there that's stopping the mechanism on the end of the gear shifting cam engaging properly. Plus when you do, drain and replace the oil with new. Sometimes that on its own works wonders.

 

[allojohn]

Definitely worth pulling off the clutch and having a look there before splitting the engine further. You might just have some gunk in there that's stopping the mechanism on the end of the gear shifting cam engaging properly. Plus when you do, drain and replace the oil with new. Sometimes that on its own works wonders.

Cheers HH, fingers and toes are all crossed.

 

[koolaid_kid]

Be sure and study up in removing and installing the clutch. IIRC, you need a special tool to install the clutch hub. And best of luck, hope it solves it.

 

[allojohn]

Be sure and study up in removing and installing the clutch. IIRC, you need a special tool to install the clutch hub. And best of luck, hope it solves it.

Yeah, I think that's right. I'll do some research.......

 

[allojohn]

The Suzuki & Clymer manuals say the tool is necessary, the Haynes manual says not so. I will find out this weekend.

While I'm in there I will replace the oil pump o-rings. Is there anything similar I should take care of?

 

[koolaid_kid]

You can file the check marks off the splines and buff the glaze off the fiber plates. Some more assistance could be here: Clutch Odds and Ends

 

[allojohn]

You can file the check marks off the splines and buff the glaze off the fiber plates. Some more assistance could be here: Clutch Odds and Ends

10-4 kk, thanks muchly.

 

[allojohn]

Took the clutch out tonight and thought I'd upload a snap of the paw. I've not been in here before so I'm not sure how it should look when stuck in 4th gear but methinks it's not right. Any comments?

 

[Guest]

Took the clutch out tonight and thought I'd upload a snap of the paw. I've not been in here before so I'm not sure how it should look when stuck in 4th gear but methinks it's not right. Any comments?

looking at the picture it looks like the centering spring may be broken. In the picture directly above the arm with the pin in the center , it looks like the spring is broken. I have seen this before.

 

[allojohn]

looking at the picture it looks like the centering spring may be broken. In the picture directly above the arm with the pin in the center , it looks like the spring is broken. I have seen this before.

Man that will be good news, I hope you're right.

 

[koolaid_kid]

I agree, that does not look right at all. On a positive note, I looked at the parts fiche for all those parts and they all appear to be external to the engine case. Unfortunately, some are discontinued, so you will probably have to go eBay shopping or ask here at GSR.
I have never disassembled those parts before, so I don't know how to suggest the next move. Hopefully someone on here knows. I will PM someone I know and ask him to have a look as to how to proceed, he may know what to do.

 

[allojohn]

I pulled the the gear shift shaft out and took the spring off - it's good. Reassembled and aligned the paw on the gear shifter. Everything works fine now. I can move up and down the gears at will - smooth as silk.

Is this significant, or am I fooling myself? I haven't fixed anything so the problem will still be there, right?

I'll put it all back together and ride it to see what happens.

 

[bwringer]

This should be fixable.

As noted, the centering spring #26 is broken.

To get at the other bits, remove the silver retaining plate #10 at the top right. You'll need to use heat and a good hammer-driven impact driver to remove those two screws. You can leave the dark gray retaining plate in place.

The shifter shaft just pulls straight out (assuming you've removed the shift lever), although there's a seal on the other side #29 you'll want to replace.

Stick a rag in that hole leading to the sump, then pull out all the bits of the ratcheting mechanism (#5, 6, 7, 8, and 9 from the fiche) and make sure everything is there and relatively undamaged.

Once these are out, you'll be able to rotate the shift drum back counterclockwise to neutral position. You'll need to gently rotate and wiggle the output shaft (a hand on the rear tire should do it) to move the gears.

If you need any new bits, you should have good luck posting in the parts wanted forum.

 

[bwringer]

I see our posts crossed paths...

Are you SURE the spring is OK? Both prongs present and accounted for?

 

[allojohn]

I see our posts crossed paths...

Are you SURE the spring is OK? Both prongs present and accounted for?

Yeah, it's good. The gear shift paw appears to have been held down by the gear thingy #5. Why wasn't it springing back is the question. I'll tear it apart now.....

 

[allojohn]

And this stuff looks OK to me too.

 

[koolaid_kid]

It appears to me that you should try to figure out why that spring popped off. You certainly do not want to do all this stuff again.