How to fix stuck gear on Suzuki Intruder VS 700?

Introduction

The Suzuki Intruder VS 700 is a popular cruiser-style motorcycle known for its reliability and smooth ride. However, over time, gears can become stuck or difficult to engage, causing inconvenience and potentially dangerous situations for riders. In this article, we will provide a step-by-step guide on how to fix a stuck gear on the Suzuki Intruder VS 700, ensuring a hassle-free riding experience.

Step 1: Identifying the Issue

Before diving into the repair process, it's essential to determine the exact cause of the stuck gear. Common reasons include worn-out shift forks, damaged clutch plates, or a malfunctioning shifter mechanism. Carefully examine the motorcycle to identify any visible signs of wear and tear or irregularities that could be causing the problem.

Step 2: Drain the Oil

Begin by draining the oil from the motorcycle's engine. Locate the oil drain bolt, which is typically situated on the bottom of the engine. Place an oil pan underneath and unscrew the bolt to allow the oil to flow out. Make sure to dispose of the old oil in an environmentally friendly manner.

Step 3: Remove the Clutch Cover

Once the oil has been drained, remove the clutch cover to access the inner components of the clutch assembly. The clutch cover is secured by several bolts, which can be loosened using the appropriate wrench or socket set. Gently pry the cover off, taking care not to damage the gasket or any surrounding components.

Step 4: Inspect the Clutch Components

With the clutch cover removed, visually inspect the clutch plates and springs for any signs of damage or excessive wear. Replace any worn-out components as necessary, ensuring that the replacements are compatible with the Suzuki Intruder VS 700 model. Refer to the motorcycle's service manual for specific part numbers and assembly instructions.

Step 5: Check the Shift Forks and Shifter Mechanism

Next, inspect the shift forks and shifter mechanism, which are responsible for engaging the gears. Look for any bent, worn, or damaged shift forks that may be causing the gears to stick. Additionally, inspect the shifter mechanism for any broken or misaligned parts. If any issues are found, replacement or realignment may be necessary.

Step 6: Lubricate and Reassemble

Apply a suitable lubricant to the clutch components, shift forks, and shifter mechanism to ensure smooth operation. Before reassembling, double-check that all parts are clean and free of debris. Carefully follow the reverse order of steps to put everything back together, ensuring tightness of bolts and proper alignment of components.

Step 7: Refill with Fresh Oil

Once the clutch cover is back in place and all components are securely fastened, refill the engine with fresh, high-quality oil. Follow the manufacturer's recommendations for the appropriate oil type and fill quantity. Dispose of the oil responsibly by taking it to an approved waste oil disposal facility.

Step 8: Test and Verify

Now that the repair is complete, start the motorcycle and engage each gear to ensure smooth shifting without any sticking or grinding. Take a short test ride to verify the effectiveness of the repair. If the issue persists, it may be necessary to seek professional assistance from a certified mechanic.

Conclusion

Fixing a stuck gear on the Suzuki Intruder VS 700 may initially seem like a daunting task, but by following this comprehensive guide, you can confidently tackle the repair process and get your motorcycle back on the road in no time. Remember to exercise caution, refer to the motorcycle's service manual for specific instructions, and seek professional help if needed. With the gear issue resolved, you can enjoy a smooth and trouble-free riding experience once again.