Is this shop tring to shaft me?

[etx]

Hey Guys. So I tore down the motor from my 94 GSX600 Katana. The trans was not staying in 2nd gear. If I was in 3rd, and downshifted to 2nd to slow down (throttle closed) it would stay in gear. As soon as I give it some gas it would slip out of 2nd into neutral. The trans parts visually look ok, exept for the side of one gear and one of the forks has a little wear on it. Here is the list of parts totaling $566 that they say they need to replace. I got them to give me the parts at cost becuase I got the bike from them, but they want to charge me 2.5 hours labor. 2.5 hours seems like a bit much, all they need to do it put the gears on the shafts, and install the shift cam and forks. I don't know, does that seem right? Basically they want to replace almost every part in the trans, here is the list.

Gear, 1st driven
Bush pn 09300-22008 (some kind of bushing I guess)
Gear, 5th Driven
Circlip
Gear, 4th Driven
Bush, 4th Driven
3rd Driven Gear
Bush, 4th Driven (Two?)
Gear, 6th Driven
Gear, 2nd Driven
Bush
Gear, 3rd & 4th
Bush Driven gear
3rd Pinion Circ
Discontinued PN# 24261-27A00 (It's $45, I assume it's another gear)
Circlip
Fork, Gear shift
Fork, Gear shift
Fork, Gear shift
Cam, Gear shift

That seems like everything in the trans! Mabye they don't know how to troubleshoot it and just want to replace everything? This is driving me nuts, I just want to ride!

[wavespy]

seems a bit steep to me, but then parts aint cheap. Have you considered a used tranny? I mean if they want to replace the entire guts of the thing...

[DrBob]

If you go to ronayers.com, they have online microfilm of the OEm parts catalog, with prices, so you can see it your shop is marking them up too much before selling them to you. 2.5 hours is not bad for a trans rebuild.

[etx]

I really think they just want to replace everything because they don't know what's wrong. I can't afford that! The prices they gave me seem good, about 40% below retail. But I honestly don't understand why I need to replace all these parts. Only 2nd gear was broken.

[Phease]

Maybe it's like when you replace the tyres on your car, they advise you replace both sides at the same time to get even wear throughout. So you don't end up with a brand spanking new gear in the middle of a used and worn 10 year old assembly?????

[Uncle Bob]

Did you ask them why they think it's necessary to change everything?

[etx]

Originally Posted by Uncle Bob

Did you ask them why they think it's necessary to change everything?

Nope, Not yet. The service department closes after 6 and I can't get there before that because I work so far away. I'm going to call them right now.

Originally Posted by Phease

Maybe it's like when you replace the tyres on your car, they advise you replace both sides at the same time to get even wear throughout. So you don't end up with a brand spanking new gear in the middle of a used and worn 10 year old assembly?????

That's exactly what I was thinking. But I still don't see that causing me to replace every part in the trans, minus the input and output shafts.

The only visual wear I can find is on one gear & one fork. Mabye due to oil starvation, I'm not sure. But everything else looks great. I just want to be sure I repair the problem correctly because I don't want to pull the motor and split it again any time soon.

[Hap Call]

It's not necessary to replace everything...it sounds like either the shifting fork may be slightly bent or the dogs may be worn and they can be re-cut.

Get your tranny back, break out the Suzuki Shop manuel and check all tolerances that they recommend. Replace only what is out of tolerence.

It takes about 30 minutes to an hout to put a transmission back together, shorter if the guy is experianced. Putting it back in the case, aligning the forks, and putting the case back together is another story...

PN# 24261-27A00 was replaced by PN# 24261-17C01, which in turn was replaced by 24261-17C02 which is listed as GEAR,6TH DRIVE at Ron Ayers. Cost $49.01

Hap

[etx]

Yeah, that makes since. It was only 2nd gear! Everything else was fine. I just don't get it. I told them I'm going to assemble the tranny myself. I have the Factory manual that illustrates the assembly of each shaft. I should be able to do it, I just don't want to buy parts I do not need.