Suzuki 2 Strokes

Hello all,
I'll be getting my rebuilt crank back from Bill Bune in the next few days. Having the crank totally rebuilt spurred me to go ahead and replace all the bearings and seals in the transmission and soda blast the cases. I took alot of detailed pics of the transmission before I took anything out but I would love to have a proper procedure to follow for reassembly. All the gears are on the shafts correctly. Just have to place it all back in. Any tips?

Just doing the same to mine apart from changing the bearings on the gear clusters. I pulled mine apart about six months ago (life got in the way) and I've just gotten around to rebuilding it. I took some photos but I really should have taken more/better/detailed ones.
I'm at work at the moment but I'll log on again tonight, as I might need to see some of those photos of yours to see if I'm on the right track

This is my set up of the gear drum and selector forks. As I hadn't taken any pics of this it took me quite a few attempts to get it to what I think (hope) is right.

Robiet,

Here's some more.
I hope they're of some help. Or is it like the blind leading the blind.

And another from the side:
I'm hoping someone can chip in here as I'm not sure if I've got those pawls in the right way round, ie, does the non-radiused edge locate as shown?

My pics aren't great either but we can at least compare. Mine were taken before any disassembly while in neutral.

Well Martin, I got mine working. Yours appears to be correct from what I can see. Is it shifting through all the gears?

Thanks for those pics Rob. I thought I had it, but now it doesn't seem to be going through the gears.

Do you have any pics of the gear drum and selector forks assembled without the gear clusters in the way? I'm sure I must have the selector forks the wrong way around as there is no way of knowing what goes where without a reference.

Before any disassembly.

Cheers Rob, that exactly what I needed. I'll give it another go again tomorrow.

It runs!!!!

CumbriaSuzuki wrote:And another from the side:
I'm hoping someone can chip in here as I'm not sure if I've got those pawls in the right way round, ie, does the non-radiused edge locate as shown?

That selector looks a tad low. That will stop the selector returning to grap the next gear between changes. Make sure the spring behind it is located correctly so that the selector is central on the pawl. I had similar on the 550 and it took a couple of tries to get right. I put a small plate across the end of the selector shaft when I did thzt to keep it in place. You'll have to turn the ouput sprocket slowly at tbe same time to allow the gears to engage - if they don't fully line up, they won't go in.

Martin , from your last picture the return spring behind the pawl isnt correctly set .