OMG, Everything but the gearbox

[Subike]

I guess you cant get a better warrentee on the repairs than from an aircraft mechanic.Good to see it working for you. Now all you need is some one to loan you a ride till the work is finnished.
sure there is somebody out the with a 2fiddy that can help you with that.
any takers?

[Sketchy_Racer]

It will most likely be the engaging dogs on the gear, not the teeth themselves.

either way it does sound like they will need to be replaced.

Good luck!

[vagrant]

Hey guys thanks for the replies, the mechenics at helipro will able to do it but I have to pay em' too, thankfully I can do it in chunks. But here is something that really threw me off. When they did the oil change, and looked at the magnet, there were hardly any metal bits. Nothing out of the ordinary, but if my gear tooth fu**s up wouldnt that mean that a metal refinery would take place in my oil system?!?!? So I'm kinda ruling out the possibility of a broken tooth. A helpful guy who I bought my back light from told me that it could be the selector... or something like that. Can anyone expand on that and any other thoughts that they may have. Thanks guys, the help is really appreciated.


Nikolai

The most common motorbike gearbox setup uses two splined shafts with the gears positioned along the shafts. Some gears are fixed and others can slide along the shaft. A set of forks move the sliding gears back and forth to mesh and combine the gears to give you different ratios.
Some gears have lugs protruding out sideways, that engage with recesses in the adjacent gear. These are called dogs. If the mating faces of the dogs and recesses are worn or damaged, the gears will try to slip apart. This puts alot of side loading on the shifter forks, and can cause rapid wearing.
Worn forks will not shift the gears sideways enough to engage fully, so the contact area on the dogs is less so they wear faster (you can see this is just going to keep compounding the problem)

Here is an article with neat animations of how it works, http://auto.howstuffworks.com/sequential-gearbox1.htm
This site also has some good photos of the components http://www.crustyquinns.com/tech/gears.html
Most bikes do the second gear dogs in before any other, it generally gets hammered pretty hard.

I had a look at the photos of your spare engine, and I don't reckon you will be fixing that one cheaply or quickly. The cases are stuffed, lots of cracks and the engine mounts look bent as well. Who ever crashed that did a bloody good job on it.

You will need to track down a manual or get the parts guy at a Suzuki dealer to compare the part numbers of the gears to see if you can use the VC motor for spares.

[FROSTY:Me]

Try this exersize. When you change into second. Hold the gearshift up -dont release the pressure. See what that does.--Wont fix the problem but may point to selector forks etc.
Me Id Hail the box out and drop the second box right on in