4sp - 5sp interchangeable gearbox internals?

Robert Critch

• 12 Answers
• Posted on Jan 07, 2009

SOURCE: Overheating

Well you need to verify the stuff already mentioned. Sparkplug, and coil etc.
The problem is likely the the coil and just needs to be replaced.
If the plug show signs of lean mix, it could have been that way for a long time (big headache).
If you just got the bike you need to kown something about troubleshooting to isolate the issue.
Makesure the oil is up. - too low could lead to a scrapped engine.
Makesure the oilpump is working.- no pump means no oil moving will lead to a scrapped engine.
Makesure you have the correct oil by doing an oil change. - bad, wrong, really old oil could mess the filter(clogged). Check filter for grit, metal, cream - if I have to explain why... then you need to give up trying to fix it yourself and pay/pay/pay for someone who has the skills to fix it for you.

If you must do it yourself, buy the Clymer manual and read.
Search the net and learn.
Get a friend to help show you how to troubleshoot the issue and fix it.

Good Luck!
Robert Critch, Barrie, Ontario, Canada - (BoulevardBob)

SOURCE: Transmission noise

if the belt is too tight &/ or misaligned, it can make nasty squelching noises!?? I found that the cush-drive hub runs on only a single bearing, off-centred to the belts pull, which could not maintain radial/ alignment stiffness, this made all the square teeth on the belt wear to a taper, i eventually had a secondary 'outrigger' needle-roller bearing mounted on the far inside end of the cush-drive hub [this took a little specialised machining] and the new belt since, now wears true!

SOURCE: lost of power

sounds like you need to refit carburator w/ a larger main jet to richen that cicuit at approx.7/8 to wide open throttle. this is very often necessary when switching from stock to aftermarket hi- flow exhaust system.

SOURCE: gas problems

I just cleaned my float bowl. Make sure to check your float measurements and the gasket on the bowl too. The gasket is a couple dollars depending how or where you order them. If the screws are stiff use PB Blaster to loosen them up with some tapping from a hammer with a screwdriver.

SOURCE: Suzuki Savage 650 LS 4 gears found not 5.

Your bike has a fifth gear. The problem is probably a bent shift fork. Broken engagement dogs could be present but I have never seen that happen in anything other than 1st and second gear. This is approximately an $800 to $1000.00 repair. Personally, I really like only having to shift 4 gears. Don't you?

Below is a partial image of your trannie and also a generic image showing how a slider gear moves left and right when pushed by a shift fork. In this example the gear dogs engage into either 1st gear or 2nd gear depending on which way the fork moves the slider gear. If the fork were bent, the slider may go into second gear but not have enough movement to reach first gear. If the gear dogs were broken off then the gear has no way to engage.

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