Suzuki 500

[ovrszd]

It sounds like it allways did .When I hit the gas it made a pop sound and did not move .I has not made any more sounds the clutchs turn the belt gose up and down on the Clutch's.The Suzuki place wants 85$ and hour to work on it .I give it to some one for parts before I will pay that.

Sounds like it has a physical break inside the transmission. If checking the linkage like I suggested doesn't help, then plan on taking the transmission apart. One last KISS principle item would be to ensure the rear clutch is turning the transmission shaft?? That clutch is keyed onto the trans shaft with a taper and a halfmoon key. There is a small chance that it has sheared that key and the clutch is spinning on the shaft. Still grabbing at straws here, but anything to keep from tearing the tranny apart. So if the clutch is truly turning the tranny shaft, next stop is opening the tranny. If you are even moderately mechnical, you can accomplish this task. Get yourself a big working area where you can lay out each piece as it's removed. Go slow. Have a clean area, including a very clean floor so when that spring or checkball gets away from you it's not lost in floor debris. The kitchen table is an idea that pops in my head but unfortunately is not seen in the wife's vision!!!! Good Luck and keep us posted!!!!

 

[Gizmo36]

halfmoon key, Man I hope that is what it is .I will look and let you know.

 

[Gizmo36]

That was not it ,it's going to be in the transmission .maybe I can find some one that wants to do some good deer hunting and do some trading on some work.

 

[ovrszd]

That was not it ,it's going to be in the transmission .maybe I can find some one that wants to do some good deer hunting and do some trading on some work.

Bummer Gizmo. Good Luck my friend!!!

 

[dsb5610]

Gizmo36,

Did you verify the transmission selector is actually working? A poster mentioned that but I didn't see your reply, maybe I missed it.

If the trans selector is working, with the clutch off, if you put the transmission selector in each forward and reverse position and turn the trans input shaft by hand the wheels should start to turn. One poster mentioned jacking the rear end up. This would make it easier assuming you can switch from 4x4 to 2x4. If the trans input shaft turns without the wheels moving then I don't see any option other than opening the trans.

dsb

 

[Gizmo36]

the transmission selector is working ,I forgot to post that .I need to go get me a Service Manuals .

 

[TOMMYHPX4X4]

That was not it ,it's going to be in the transmission .maybe I can find some one that wants to do some good deer hunting and do some trading on some work.

when you turn that rear shaft does it turn freely when in gear or does it turn the wheels. did you check the splines on the clutch pulley itself?

 

[Gizmo36]

When I turn the rear shaft it does turn freely when in gear and out of gear.

 

[TOMMYHPX4X4]

internal gear is shot. get a manual for about $40.00 i had a honda 125 four trax and the gear went out sorta like that and it cost like 65 bucks. but with a manual it was a piece of cake to change. if your machanicly inclined guy it should be about 3 hours worth of work at the most.