Suzuki sticks In Reverse
Seller was up front about a shifting problem and was asking a very fair price, I looked at it and felt that it couldn't be too complex. I have quite a bit of experience with mechanical things and it's a simple linkage, so bought it and brought it home.
I guess that's what I get for thinking. When looking at it, he had a flushing muff on it and fired it up. Runs nice. Shifted into F, no problem. Back to N, no problem. Shift into R....fine, but it wouldn't shift back to N. Gearshift was jammed. With motor turned off and shifter cleared, it shifted back and forth, no problem. Only when it was running. (?????)
I brought it home and disconnected the shift linkage just above the gearcase and the gear shift handle and linkage all seemed free and smooth, so figgered the problem was in the gearcase mechanism.
I disassembled the gear case and found the shifting cam to be deeply gouged on the R face. Not sure what would cause that - I see no signs of it having been run without oil, but with the small diameter plunger that sits on there, I could see how it could cause a problem. Sooo....ordered a new one. $20 bucks. NBD.
He did give me a box of odds & ends with it, and much later got to digging thru it. I found the broken transfer bar and also an old shift lever that's badly gouged/scraped. No other signs of damage anywhere. Looks kinda like it was dragged along a roadway, but again, no other signs of damage. Look at the angles and depths of the scrapes. How on earth did they manage that ??
Over the past couple of days, I installed the new shift cam and reassembled the motor. Started it up, it runs fine....shifts fine....but sticks in reverse. No change. The old, broken transfer part between the shift handle and the central shift rod is in the box of goodies, so they replaced that. Nothing seems bent or sticking.
With it still on the bench and gearcase reassembled, I tried pulling on the shift rod with my fingers and shifted it in and out of F-N-R with moderate pressure - with my fingers, remember - so definitely not jamming or sticking.
I left the clutch and shift rods disconnected and went up to the shift handle. Smooth and clean, no binding or sticking anywhere - it's a new part - and white grease all over the moving components. No evidence of anything bent or broken.
Reassembled everything and fired it up and it still sticks in R.....and no fooling. I can push as hard as I dare on that shift handle and it won't move out of R. Turn the motor off and try turning the prop and it "pops" with light pressure like it's stuck in gear, then the shifter moves freely.
I'm completely baffled. I had that gearcase apart. The gears, dog clutch, plunger, spring, pinion, etc., all look very good and move freely. No evidence of wear or breakage. Looking online has been no help at all.