What kind of motors do you rebuild? Sounds like the old 2nd gear fork going bad to me. You will have to remove the motor and split the cases to access the transmission. The good news with that motor is that you can actually split the cases without having to tear the top-end down to access the transmission.

- Nut

 

Just small 4 cyl's to build up with forged internals. I have a new vq35de in my 350z, it's aluminum with sleves so I have not tackled that beast yet.

So I will have to pull the motor, split the case and replace the fork? I'm going to need to find a good service manual. Any recommendations?

 

Like nut said, the 2nd gear problem will require opening up the engine. As for the clutch, it shouldn't be that heavy. My first guess would be that the cable itself is hanging up. It's cheap enought to change for a first shot.

 

I would get both a Clymer and the shop manual. Also take a good look at the first driven gear when you tear it apart. Normally, they need to be replaced as well on higher-mileage or abused O/C motors.

- Nut

 

I think I saw you on a different post but, 2nd gear is gone. By saying that I mean you will have to replace the auctual 2nd gear on the mainshaft and the gear it engages with on the same shaft (engagement dogs rounded off). You'll most likley have to replace a shift fork, and shift drum too. (Don't forget new snap rings). Its a major undertaking and like the others said, you'll have to pull the motor and split the cases. As for the clutch, perhaps someone put a Barnet clutch in there, known for stiff springs and the tendency to creep in neutral. Do yourself a favor and try to find a Genuine Suzuki service manual. It may cost more, but its worth it.

 

Yep, I just ordered a Suzuki manual. I'm going to pull the motor and split it open. So does the trans come off of the lower end of the motor? Or is it one casting? Thanks for your help guys!

 

When you split the cases both trans shafts, shift drum, and shift forks all stay in the upper half of the case. Which is useful, for when you reassemble it you can go through all the gears and visually see it all working.

 

Ok! I have the case open. Visually everything looks ok, no signs of major wear. But I still need to find a vernier caliper to check all the clearances. Any idea what I should look for? If the price is right I may just take the easy way out and replace the gears, forks, and drum. But I would rather not do that :wink: . Thanks!

another thing.. My clutch has 6 bolts / springs, not 4 like the manual shows. Did they change something in 1994 models? Or mabye this is an aftermarket clutch?

 

eeeeh. Bump?