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Grinding gears when shifting after reassembly. (Read 147 times)

verslagen1

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Re: Grinding gears when shifting after reassembly.
Reply #15 - 10/09/22 at 22:25:54

Moarpower wrote on 10/09/22 at 20:14:36:

I will add that the previous owner had 2 small coins with holes in them used as makeshift washers or spacers installed under each of the 4 clutch springs. I removed them this time. I adjusted to free play in the clutch to be about a quarter inch. Now it is giving a grind when I try to push it into gear, but when in gear, the rear wheel moves for a moment but then stops and spins freely. The same for all gears. Could the coins have been installed to combat the wear on the clutch and now removing them has mad it not work properly?

The coins were probably put in to prevent slipping.

If you do this you need to check if the springs are bottoming out which could break the throwout cam.

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verslagen1

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Re: Grinding gears when shifting after reassembly.
Reply #16 - 10/09/22 at 22:31:48

Moarpower wrote on 10/09/22 at 20:14:36:

When I was torquing down the clutch locking bolt on the shaft, the shaft did rotate clockwise a few times and made a twangy sound that did worry me, but it would always turn the rear wheel when I was rotating the shaft.

I hope you have a bike made after '95, the twangy sound was probably the starter torque limiter on the other side. When you turn the engine backwards the starter clutch engages and tries to turn the starter backwards. This takes a lot of torque and early model bike w/out the limiter break teeth or bust out the mounting bosses for the gears.

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Moarpower

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Re: Grinding gears when shifting after reassembly.
Reply #17 - 10/09/22 at 23:54:20

verslagen1 wrote on 10/09/22 at 22:25:54:

The coins were probably put in to prevent slipping.

If you do this you need to check if the springs are bottoming out which could break the throwout cam.

What do you mean by bottoming out? Compressing all the way when installed? I removed the coins for now.

In regards to the bike year. I have an 87 but have 2004 model starter gears

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verslagen1

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Re: Grinding gears when shifting after reassembly.
Reply #18 - 10/10/22 at 07:37:27

Moarpower wrote on 10/09/22 at 23:54:20:

verslagen1 wrote on 10/09/22 at 22:25:54:

The coins were probably put in to prevent slipping.

If you do this you need to check if the springs are bottoming out which could break the throwout cam.

What do you mean by bottoming out? Compressing all the way when installed? I removed the coins for now.

In regards to the bike year. I have an 87 but have 2004 model starter gears

When you pull in the clutch the springs will be compressed more.
If they bottomed out then, they'll overstress the throwout cam and snap it in 2.

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TheSneeze Serious Thumper Offline Posts: 1313 Northern Nevada Gender:	Re: Grinding gears when shifting after reassembly. Reply #19 - 10/10/22 at 07:54:50 If you do ever break the throw out cam, I have made replacements that are much stronger. PM me if interested.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Grinding gears when shifting after reassembly. Reply #20 - 10/10/22 at 16:08:31 How would I be able to tell if it's bottoming out? What is just be noticeable is the handle?
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Grinding gears when shifting after reassembly. Reply #21 - 10/10/22 at 16:15:45 Currently I'm just able to shift into gear without pulling the lever and then there's no movement. I think that's because I removed the coins. Hoping the new plates and springs solve all of these issues. Some of the friction plates are nearly flat.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: Grinding gears when shifting after reassembly. Reply #22 - 10/10/22 at 16:52:50 Moarpower wrote on 10/10/22 at 16:08:31: How would I be able to tell if it's bottoming out? What is just be noticeable is the handle? sudden stiffness in the lever.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Grinding gears when shifting after reassembly. Reply #23 - 10/10/22 at 17:32:43 Ok. Theres no more resistance than usual
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Grinding gears when shifting after reassembly. Reply #24 - 10/11/22 at 19:31:10 Clutch plates arrived. Waiting on springs and thrust washers.
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