Suzuki VS800 trike

chilterns · Posted: Fri May 28, 2010 11:58 am Post subject: Suzuki VS800 trike

Sorry, posted this in the wrong forum section (Members projects)

I think this is the right one.

My 1997 Suzuki VS800 Intruder (triked sometime prior to 2005) only seems to have (has) only 4 gears. Everything seems to work OK - nice crisp gear changes, although neutral seems to be hard to find at times.

It seems, according to the service manual for the VS750GL/800GL that they are all supposed to have 5 gears from as far back as 1986.

The frame number is VS52A-111068 and the engine number is S503-130464, although this should not make any difference as it "should" have 5 gears.

I know some trike builders eliminate/disable the 5th. gear due to the extra weight of the trike and rear tyre size, although this is not the case with my trike (I checked with the builder).

Does anyone have an explanation.

dbj · Posted: Sat May 29, 2010 5:38 am Post subject:

ok well its only a "my tuppence worth" but my initial best guess was selector wear :

It seems to me that something is worn and working into that worn area may create a catch. Possibly a slightly bent shift fork pin.

One of your shift forks has a replaceable pin.

Another thought is on that shifter detent there are 2 tiny springs in there. That could be worn since it is a thin piece.

was the best info from one of the motorcycle mechanic sites, my rule of thumb info was that the selector does more work the further up the gears it goes so loosing top would suggest wear.

chilterns · Posted: Sat May 29, 2010 6:01 am Post subject:

Thanks for that dbj. I'm trying to get a consensus before I start dismantling things, so your opinion will be in there.

Mel

dbj · Posted: Sun May 30, 2010 1:50 am Post subject:

have you done a recent oil change i.e. post the missing gear?

just if the answer's a no then a change and sieve the old oil to look for fragments might be worth a try, might not be good news but at least you'd have a firmer idea where the issue might be.
bent selectors dodgy springs and just plain general wear won't really show up but at least you know that it should trundle along for a few thou more before anything really causes issues, bits of metal in the oil and maybe now is the time to rebuild Smile

yet again rule of thumb as bits of metal have a habbit of hiding until you really need the engine running fine and that's when they appear to scupper whatever plans relied on them Smile

chilterns · Posted: Sun May 30, 2010 8:47 am Post subject: Suzuki VS800 trike

Wow dbj, you're making me depressed now - "bits of metal"

Yes did an oil change a couple of weeks ago, but didn't notice any bits - it's had an oil change previously after I bought it.

Mel

SHAUN · Posted: Sun May 30, 2010 11:28 pm Post subject:

again i also agree it could very much be a worn selector, you could drain the oil and remove the side case to gain part access and use a pen torch to look at the selector it may tel you loads or it may not. i did this when my son smashed a gear on his cb125 a few months ago and found the bit, as well which gear was bust. a flexible pen torch would be best.
i hope this helps, good luck and i hope its simple to put right.

chilterns · Posted: Mon May 31, 2010 3:21 pm Post subject:

Thanks Shaun

Mel

dbj · Posted: Sat Jun 19, 2010 11:44 pm Post subject:

if you have a good look and cannot find any wear or obvious faults seem to remember there are some small springs in the selectors that may need a change ....

to be honest i'd probably pick the brains of the "best" main dealer mechanics you can find and make up a homebrew "recon" kit
you always have to watch for the one that wants to sell you a new bike in parts Smile

but .... they normally see a fair few "age" with the same faults at the same mileage ... and ... they can normally stop the repair one part only for another to fail that could have easily been replaced when doing the 1st if ya get my gist ...

think i may have a manual for something very similar floating around in pdf form somewhere if its any use to you....

chilterns · Posted: Sun Jun 20, 2010 9:15 am Post subject: VS800

Thanks for that dbj - I'd appreciate a look at the pdf if you can find it.

I've just tried the gears again with the trike stationary and seem to get all the gears "clicking" in, but not tried it on the road yet, but would still like to see the pdf.

Mel

Just road tested the trike and the gears work a treat. As I had fitted forward controls there was probably too much friction in the linkage, preventing the shift pedal returning to resting position. I loosened the linkage and applied some magic WD40 and all seems well.

I love a simple solution

I'd still like to see your pdf though dbj

Mel