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Locked up Trans on 2001 DRZ 400
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Posted by: Poolman---------------------
My transmission locked up yesterday and will not shift out of, or into any other gear. Kick starter is even frozen. Anyone else ever hear of this? Anyone know of a good place to take this bike in the So. Cal. area to have it repaired?
Scott Please e-mail me
Posted by: idahodirt---------------------
I had this happen on my XR600. One of the gears broke a tooth and it wedged in between two gears. Had to replace a couple gears and the crank bearing. At least it happened at the top of big hole I was in so I was able to take the chain off and push it out to a forest service road, call the wife on the cell phone to come rescue me.
Posted by: biglou---------------------
Poolman-Get in touch with DRN member CAL. He had his 2000 do the same thing. It wasn't pretty. Just send him a PM and he can fill youin on all the details. Also, he has a picture or two of the parts involved in his member gallery if you want to take a look. I gotta warn ya, it wasn't cheap to get it repaired. Around $750 if I remember correctly.
Posted by: CAL---------------------
Yep. I, unfortunately went through the same thing. I was riding along (easily) when the bike jumped out of third gear. I went back into third and them BOOM! I went down to first...it was fine, second was fine, third was gone, fourth was fine. I then went back down to first and it hung in first gear. It started fine though. But mine's an E so it doesn't have the kick start assy. gears. I rode back to the truck in first gear.
According to the mechanic, the shift fork had gotten bent some how. That bent shift fork caused wear on the shift dogs. The wear and tear on both the shift fork and dogs lead to a failure of the shift dogs between third and fourth gears. And the broken dogs bounced around and took out the shift drum and 2nd through 4th gears. So I had to replace 6 gears total, a shift fork, one bearing, washers, spacers, gaskets, and have the shift drum machined. That plus 6 hours of labor cost me $750 and 8 weeks without riding. The gears were about $60 ea., the shift fork was about $40, and the gasket set was $107.
I ran Mobil 1 15w50 and changed it every 20 hrs. The mechanic was certain that the failure was in no part my fault, and was a stress failure in the parts. But the great thing about having dirtbikes without warranties is...you get to pay for any problems...even if they are Suzuki's fault. If your bike is under warranty, I would make sure they cover it. Spending $750 on your bike and ending up with the exact same bike you had before the $750 really stinks!
Now that your good and depressed...if I can help in any other way let me know.:silly:
Here's a link to my photo gallery. Click on it, and look for my tranny picture.
Click Here
Posted by: CAL---------------------
Make that pictures...not picture.
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