I made the idiotic decision to rip apart my motor before I deployed with the hopes of having the bottom end back together before I shipped....boy was I wrong.....I'm having a hard time getting the trans back together and operational.I did take pics,and put them on my computer......but my computer got a virus and all was lost -_- just my luck.so I'm hoping this can be my help me thread.my first road block is the ratchet mechanism,I don't think I have it together right.I got the cases together and I'm kinda positive its together the way it should be,wont know till the ratchet thingy is working properly so I can run it through the gears on the bench.......and so far,turning it by hand,it seems 5th and 6th gear has a bunch of resistance and sometimes it doesn't want to downshift smoothly,almost like it binds.I'm in way over my head but I'm determined to learn this
****!!!! Im trying to figure out how to post pics from my phone so yall can see where im at with this.i know its vauge but any tips tricks pictures or discription helps!!!!
Did you split your cases or just remove the clutch side cover?
First thing the trans won't shift without turning the. Countershaft it needs vibration and motion to jockey the gears.
Try that first. I usually roll them through the gears before I put the center cases back together.
I just did mine last season and here's what you need.
Go here:
http://www.suzukipartshouse.com/oemparts/a/suz/50d09298f870022e9cc419d8/transmissionRight click on the fiche picture and "save as" to your desktop then print it out full size. Once you got this you can use it as your guide, do note that it can get a little confusing as the picture is upside down and/or reversed compared to your trans if you have the left side case on the work bench and your building off of that. Which is how it was recommended I work and it went pretty good.
So once you get your mind twisted around which shaft goes where and goes which way it's pretty easy.
Build yourself a motor box out of 2x4's so you can prop up the motor and have the shafts stick out and the case laying flat on it's side while your working on it. Can't remember the exact optimal size but Interior dimensions are like 7" or 8" by 9" or 10"
Commandeer yourself a plastic serving tray from a fast food restaurant, this works great as a parts tray where you can lay your stuff out and keep it organized.
Get yourself a magnetic parts tray from Harbor freight to layout the little stuff so it does not fly away on its own.
And I take duct tape and tape my bolts in to a package in the order they came out marking the starting point so they go back just like they came out.
I know there are a few more tips more specific to working on the bottom end I just can't remember them right now...can someone else jump in here?
Thanks for the input,
-yes the cases got split,Im attempting a full rebuild on muh baby.
-I know that the shafts need to be spun to catch the next gears but sometimes its not as smooth as I would expect,and the binding when downshifting from 6th to 5th,I'm afraid to run it and have it hand grenade my cases,I have over 2g's in this restoration so I'm taking every caution I can lol.
-thanks glamis rider,but since my comp craped out on me I am going to have to see if the work computers will alow me to see all the goods.
- I feel that I should at least give a further discription of my ratchet woes since I can't produce a picture,when I was taking the motor apart this little part caught me by surprise as it fell apart before my eyes without me realising what it was at first....so I drop the spring in first,then the pin with the flat side on the spring,round end to round in and the cutouts hold the pin in and everything is flush........but now it doesn't ratchet it just wants to do a full turn along with the shift drum.
-everything got seperated in the ziplocks and tagged.so far that's my only saving grace.and I have 3 shitty pics on my phone still,but they only help when I get to installing the acessory drive gears in the clutch side.
Sorry thought you had a 500 ( I always assume this for some reason
The Pawls need are shaped different on the ends so make sure you have them facing the right way in to the pocket so they can pivot and I also believe there is a inside Vs outside ?
Oh yea one of the tips was when pulling the pawls out slowly release them otherwise the springs will fly out.
Let us know
So this is my attempt to upload a pic from my phone,if it doesn't work I'm at a loss with uploading pics till I get my comp up and running.
Guess it failed,would anyone be up for pming me their number so I can send a vedio and pictures of the problem?
Can u upload to photobucket?
I have the pic loaded to photobucket now,but our military computers at work are restricted as hell so cant upload it there and my smart dumb phone is leaning more toward the dumb side of life,I downloaded tapatalk with hopes that would help but can't find this forum on there.and that my friend is where I am beat by technology -_-
Chatting with a good friend from back home,he said the bearing retainer may be what dissengages one side of the pawls to achieve that ratchet.I'm heading back to my room during lunch to see if that's what I was missing.I am going to feel so retarded if it was just my retainer.I have to much money invested so I'm slightly nervous lol
So public humiliation hour......turns out bearing retainers do more than retain bearings!!!! All is well now and if I can keep my derp moments at bay for the rest of the time I should be buying race fuel for it this weekend!!! Ill figure out pics and show off my first build.hoping to have it at huckfest if any of you are going to be there id love to meet y'all
Yup I was gonna try to get there... Trucks flying outta be insane
if any of you are going to be there id love to meet y'all
Hahaha, all that I could think of when I read this was
^ please go to funnyjunk.com to view this image??? O.o