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Suzuki 800 Intruder Club & Forum

A UK Site Dedicated To The Suzuki C800, VL800, VX800, M800, VZ800, VS800, C50, M50 Model Intruder / Boulevard / Marauder
 
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 Sticky Gearbox

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yorky
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PostSubject: Sticky Gearbox   Sun Feb 02, 2014 6:12 pm

Any advise please....Bit the bullet and ventured out this afternoon...sunny but cold.

Only got a couple of hundred yards and found it just about impossible to change gear. Could go into second but no further and very tight moving between first and second and gear leaver seemed to be stuck in an unsusual position ( High at the front )

Got back home and had a look but couldn`t see anything wrong, checked tightness on splined shaft coming out of g/b...o.k.

But gear shift still very stiff and sticky. Sprayed linkage with WD and kept working by hand and slow but sure slowly got better.

Ventured out again and could get all gears but still a bit stiff.

Bikes  30 months old with little use. I`m a bit surprised as to whats going on !  Just hope its `dry` linkage and nothing worse.

Has any one had similar
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captain crash
Mentally Deficient lunatic ..... & ..... Site Moderator
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PostSubject: Re: Sticky Gearbox   Sun Feb 02, 2014 6:22 pm

Sounds like linkage cause you say manipulation was making it better but I don't know if that would help something inside that had got stiff
Is your oil change up to date?
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simbo
.. Mechanical Tart .. .. Site Moderator ..
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PostSubject: Re: Sticky Gearbox   Sun Feb 02, 2014 6:36 pm

Sounds like either the nut on the back of the gear lever is to tight or some crap/rust has built up over time? I'd suggest taking the nut off and removing the bolt and cleaning and greasing them, there's also a couple of spring washers in between the lever and frame to stop vibration, only thin things, so keep an eye on them.
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Mr Intruder
Suzuki800.com Founder ... & ... Senior Administrator
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PostSubject: Re: Sticky Gearbox   Sun Feb 02, 2014 7:09 pm

Good advice given so far here, nothing to add from me.  
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fat intruder
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PostSubject: Re: Sticky Gearbox   Sun Feb 02, 2014 7:11 pm

I'd have a go at what Sim said my side stand and gear change where stiff side stand was the worst had to kick it with my heel to get it up I put engine cleaner all over bike jet washed it let it dry then used chain lube and wd40 stand springs back up with the smallest nudge now and gear change is easer was just all the shite of the roads plus salt also lubed up my back brake as that was getting stiff as well
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MarcinG
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PostSubject: Re: Sticky Gearbox   Sun Feb 02, 2014 7:11 pm

8000 posts nearing eh Dave? ;D
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yorky
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PostSubject: Re: Sticky Gearbox   Sun Feb 02, 2014 8:01 pm

Thanks guys
......I`ll dismantle and have a closer look.

Crash ..only done 1600 miles ..I changed oil when I got it 2 months back ...it would be nasty if it was something inside !!
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peardrop3
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PostSubject: Re: Sticky Gearbox   Sun Feb 02, 2014 8:18 pm

Morgan you greased your rear brake? Hope you remembered to wipe the excess off the shoes matey      affraid
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Doc Cox
The Nutty Professor
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PostSubject: Re: Sticky Gearbox   Sun Feb 02, 2014 9:47 pm

Yorky, pull the rubber boots off the joining linkage and  see if they are rusty or just dirty, the boots are a good idea but will trap condensation.
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Two-Bears
* VZ Guru *
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PostSubject: Re: Sticky Gearbox   Mon Feb 03, 2014 6:58 am

Hi Yorky,
Apparently this is a fairly common problem on VL800 and C50/800 with the gear shift sticking and not returning after gear selection, Suzuki I believe upgraded the shifting bush ( Number 42 in the exploded view ) and changed it  from 2009 onwards to bring in in line with the C1800/M1800 so your bike should be done but it appears you still have the problem,,, pulling the bush out and cleaning it and wiping all grease off and re-assemble with oil would probably help ( oil and grease attract dirt particles and capture them which eventually jam up the works,,, oil traps dirt particles less so ) You can actually buy modified bushes to eradicate this problem,, they are made from a permanently lubed bronze,  http://www.gmanindustries.com/shop/pc/GBushings-Shifter-c48.htm 
I also agree with Nigel and would clean and lub under the rubber gaiters of the knuckle joints either end of the gear shift rod.
Hope this is of some help mate.


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yorky
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PostSubject: Re: Sticky Gearbox   Mon Feb 03, 2014 9:20 am

Thats a load of help John and Nigel.

Im in there today ( garage ) and  dismantling the assembly and give it a good clean and lube ( oil not grease )

I was flapping yesterday thinking I had bought a bike with only half a gearbox !!

As ever just the onfo. I needed thanks all.
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simbo
.. Mechanical Tart .. .. Site Moderator ..
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PostSubject: Re: Sticky Gearbox   Tue Feb 04, 2014 4:51 pm

How did you go on with the sticky gear lever Alan?
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yorky
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PostSubject: Re: Sticky Gearbox   Tue Feb 04, 2014 6:27 pm

You were right Sim.
The bush for the lever is a bit crude ain`t it. ( item 42 on Two Bears splendid dwg. )
As you said it was bone dry inside and thats where it had got tight.
Little rub with emery then all back together, bit of lube under rubber covers and sweet as a nut.
Low and behold sun was shinning and roads dry, so with the new slick gearbox I had a little blast.
Only about 10 mile but it was great. Even had a couple of mile on the motorway and became a bit of a hooligan.
I`ve not had chance to put many miles on the bike but I was pleased with how it went and how it can hold its own on the motorway.
Thanks to everyone who chipped in with info.
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simbo
.. Mechanical Tart .. .. Site Moderator ..
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PostSubject: Re: Sticky Gearbox   Tue Feb 04, 2014 7:10 pm

Yorky wrote:
Even had a couple of mile on the motorway and became a bit of a hooligan.

   Glad you got it sorted Alan  
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captain crash
Mentally Deficient lunatic ..... & ..... Site Moderator
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PostSubject: Re: Sticky Gearbox   Tue Feb 04, 2014 8:39 pm

nice one Alan, funny how simple unexpected stuff can really get you thinking   
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Mr Intruder
Suzuki800.com Founder ... & ... Senior Administrator
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PostSubject: Re: Sticky Gearbox   Tue Feb 04, 2014 8:57 pm

Glad it was an easy fix Alan.  
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alfie92
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PostSubject: Re: Sticky Gearbox   Tue Feb 04, 2014 10:00 pm

Sound made up for Alan,the quick cheap fixes are always the best.
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