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Just brought an old ts 185 thats a 1984 model... apparently the problem with the bike is that the motor and gearbox was rebuilt and since this happened the second gear fork comes off.... i only got the bike last night and havent pulled it down yet... any advice or diagrams would be marvellous... im a mechanic but havent had much to do with bikes... thankyou!!
You say the second gear fork comes off. Do you mean the bike pops out of second gear while riding? Dose the bike shift smoothly up and down through the gears?You say the second gear fork comes off. Do you mean the bike pops out of second gear while riding? Dose the bike shift smoothly up and down through the gears?
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Google " service manuals suzuki " or go to www.repairmanuals.com or try your local library. Often guys will donate manuals to the library. You might find a free pdf service manual on this site, they have a ton of them. http://www.carlsalter.com/motorcycle-manuals.asp Please rate this solution. Thanks junior7mm!
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Hi, does this bike backfire at all? Noticable as the kickstart hits you hard as you try to start the bike, these bikes used to suffer with cdi ignition failure, eventualy breaking the kickstart ideler gear inside the gearbox which in turn the oil pump drive was also fitted to this,
The bike has a bent shift fork in the transmission. You describe the classic symptoms. The engine will have to come out of the frame. Then it gets flipped upside down, right and left side covers, shift shaft, and other components are removed, then the bottom half of the gearbox is removed. This allows access to the shift drum and shift forks. There are some special tools needed and I don't recommend a novice mechanic tackles the job. Below is a diagram of how the shift drum moves the shift forks left and right to make a slider gear engage different gears. Please rate my answer. Thanks.
ts 185 is a two stroke, the crank case oil is actually only the gearbox oil, the volumne is caste onto the side cover(like 750cc).near the filler cap. The engine oil is mixed with the fuel and is pumped in from the oil tank under the seat. The wrong oil or no oil in the tank under the seat can cause it to lose compression. and cause engine damage. Visit a bike shop and get motorcycle gear oil20w50 for gearbox. and two stroke motorcycle engine oil for the oil tank. As it is quite old someone may have removed the oil tank, thinking they will make it go faster or save weight or another stupid reason, if this is so you need to mix the two stroke oil with the petrol when you fill the tank at approx 25-1 ( 25 litres petrol mixed with 1 litre of oil)
Hi This does sound like a gearbox problem, either where the cogs lock together (the dogs go into recesses) or the shift forks themselves The dogs do wear after high mileage which can make them slip out of gear Ive never heard of a gearbox smoothing out over such low mileage, but I suppose it is just possible You could get the gearbox 'blueprinted' (i.e. to manufacturers exact specifications) but this will cost a bomb ! Your best bet is to complain again & at least get a ride on another rocket3, or get it sorted under warranty
Ride safe
Bike-Doc
Please mark this as very helpful (if it has been!!)
(great old bike Kevin) Sounds like selector forks, cams and/or grooves on selector barrel are at wear limits. Drain gearbox oil over magnet and check for metal splinters. Metal silt is common but shiny shards (very small) or foil like pieces indicate excessive wear. These old girls will still keep turning but will jam eventually. I suggest you pull selector mechanism down and either shim behind the cam plate spring or get replacement selector barrel. In the mean time thoroughly flush and give her some good quality gear oil of the lighter viscosity. Drive and driven shaft end bearings are often at fault on long haul m'bikes also. Replacement is inevitable.
The gearbox does not need to be relpaced. The bike has a bent shift fork. The engine comes out then gets a complete tear down to get to the bad fork. This will probably cost $1200 or so. Call a dealer and get an estimate. Please rate my answer. Thanks.
You may have some damage in the transmission. See if the shifter lever feels free, and returns, as if it binds up can cause this problem.
If that seems okay, try rocking the bike back and forth to see if it helps shifting (engine off in gear) Otherwise, you may need to go deeper inside.
Sounds like it needs to be split.
You could have a bent shift fork, or worn shift drum. This is not a "simple" job.
I've also seen where gears mesh chewed up or rounded off.
Get it opened up!
I had exact same problem.. bottom line I had to replace selector forks (all three) and second gear cog.. If u do replace a gear cog then please take a tip from me (lesson hard learn't). Have all your gears undercut at the same time or it will slip out of another gear.. I got my bike back after 2 nd gear done and on the same day 3 rd gear started to slip. Had to send bike back and have all the cogs undercut... Now its fine.
And yes u do need to remove motor to open gearbox and u will need to replace gaskets..
You say the second gear fork comes off. Do you mean the bike pops out of second gear while riding? Dose the bike shift smoothly up and down through the gears?
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