I fully rebuilt the engine on my kettle a few years back. After a few hundred miles the dreaded 3rd gear slippage started to happen. Grrrr! Anyhoo, I put up with it until now. I want to sell the bike so it needs to be put right.I sourced a very decent pair of replacement 3rd gears (Drive and driven pair), took the plunge and hooked the lump out last week. Dodgy gears now replaced and reassembly well on the way
Very pleased that the rest of the internals are like new,
Kettle engine rebuild
- canaletto5
- Posts: 5228
- Joined: Tue Jul 23, 2013 8:43 pm
- Location: Derbyshire
- Alan H
- Posts: 12110
- Joined: Fri Aug 05, 2011 6:38 am
- Location: Wombwell, Republic of South Yorkshire
Re: Kettle engine rebuild
Pity you didn't let me know, I've 'several' spare gearboxes bud.
Proof that four strokes are over complicated
- canaletto5
- Posts: 5228
- Joined: Tue Jul 23, 2013 8:43 pm
- Location: Derbyshire
Re: Kettle engine rebuild
Me too mate A little detail is that the 3rd gear on the B is a different ratio from all the other years. Typical Suzuki
- Alan H
- Posts: 12110
- Joined: Fri Aug 05, 2011 6:38 am
- Location: Wombwell, Republic of South Yorkshire
Re: Kettle engine rebuild
They did that on 550s as well.
Proof that four strokes are over complicated
- canaletto5
- Posts: 5228
- Joined: Tue Jul 23, 2013 8:43 pm
- Location: Derbyshire
Re: Kettle engine rebuild
Indeed, the parts are intre intercheg intocharge you can swap them about
-
- Posts: 1035
- Joined: Mon Mar 07, 2011 8:10 pm
- Location: Chicago
Re: Kettle engine rebuild
They changed a few different gears over the years, but all wear the dogs on 3rd. They get rounded off and eventually spit out of gear and take the two gears either side with them.
NOVA sell replacement gears. Not cheap but cheaper than getting all the dogs built up and reground if you really only need a couple. I have over a dozen sets of gears here and they all show some wear on the dogs.
The 8 valve GS750 had a few gears with better dogs and the 8 valve replaced some more. The best combo is an probably an early model GS750 with late model gears where required. It doesn't take a lot of modification or machining to fit.
NOVA sell replacement gears. Not cheap but cheaper than getting all the dogs built up and reground if you really only need a couple. I have over a dozen sets of gears here and they all show some wear on the dogs.
The 8 valve GS750 had a few gears with better dogs and the 8 valve replaced some more. The best combo is an probably an early model GS750 with late model gears where required. It doesn't take a lot of modification or machining to fit.
- canaletto5
- Posts: 5228
- Joined: Tue Jul 23, 2013 8:43 pm
- Location: Derbyshire
Re: Kettle engine rebuild
Good knowledge Teazer. The replacement gears I'm using are from a GS750 as the 3rd gear set is identical to the Kettles and fits directly.
-
- Posts: 1035
- Joined: Mon Mar 07, 2011 8:10 pm
- Location: Chicago
Re: Kettle engine rebuild
As long as you have a late A or B model, an 8 valve GS third gear should drop in on the output shaft. On earlier models it would physically fit on the shaft but it would have 1 tooth difference and may cause backlash issues.
The 16 valve (GSX in the UK, still GS in the US) has different dogs.
I ran a slightly modified 8 valve GS transmission with 16 valve gears to take advantage of the stronger dog design. The dogs are identical to any GS/GSX1100 but the 1100 trans is wider and takes more work to fit - don't ask me how I know.
The 16 valve (GSX in the UK, still GS in the US) has different dogs.
I ran a slightly modified 8 valve GS transmission with 16 valve gears to take advantage of the stronger dog design. The dogs are identical to any GS/GSX1100 but the 1100 trans is wider and takes more work to fit - don't ask me how I know.
- canaletto5
- Posts: 5228
- Joined: Tue Jul 23, 2013 8:43 pm
- Location: Derbyshire
Re: Kettle engine rebuild
Hi, yes, mine is a B so the gs750 gears are directly compatible
- Dutch
- Posts: 756
- Joined: Thu Jul 28, 2011 8:28 pm
- Location: St Helens Merseyside
Re: Kettle engine rebuild
Hi Alan, have you got a good 4th gear for me? Mine whines when in 4th
Cheers Jeff
GT750A