Gearbox failure and warranty?

I suspect that "required" should be changed to "allowed" though.

Call me a sceptic.

just looked in my warranty book.

Servicing
The machine must be serviced as recommended by the manufacturer at the intervals specified in the appropriate Suzuki Owner's Manual.

It is the owner's responsibility to ensure that the dealer has recorded and authenticated the service by completing the appropriate section of the service record at the rear of this booklet.

hmmmz. I just changed the oil at 4000 miles. I hope it doesn't bugger the warranty up

Continuing to ride it was a risk but would never have cost as much as what I was going to miss.

The servicing hasnt been done by a Suzuki dealer since 1000miles but the reason I have gone to see them about this is a gearbox should last longer than 7300miles regardless of the service status.
It was an educated decision not to keep the service record as SVs dont go wrong!
I am aware that I may have to pay for/ fix it myself and will not be too upset about it.


Now onto the dealers,

Cusworths in Doncaster- They were happy to speak to me and phone me back but as soon as they realised it was not sold by them they gave a 6 week lead time for the workshop and recommended I went elsewhere. (they did this was a mate on the recall for CBR rear brakes, so not entirely unexpected)

George Ward in Barnsley- Great. Said drop by so they could have a look. I spoke to them and told them the full story and history, a couple of knowledgable guys from their also very busy workshop came out to have a look and diagnose the problem. Obviously without the service history intact it is not a clear cut case but they are willing to check with Suzuki. They also have a complete engine and gearbox out of a bike they have just broken which is another option.

The diagnosis is a problem with the 1-2 selector, the grinding noise stops when the bike is leant over to the left but worse leant to the right.

Originally Posted by ivantate

It was an educated decision not to keep the service record as SVs dont go wrong!
I am aware that I may have to pay for/ fix it myself and will not be too upset about it.

Everything mechanical has the potential to go wrong, but big thumbs up from me for the relaxed attitude about it.

Search the org for Ed's posts about unfair terms for consumers, I suspect it might come in handy to at least argue with Suzuki, if you wanted to (or needed to) go down that route.

Keep me posted as to how you get on, since I do my own servicing now on a 10month old bike. Dealership servicing wasn't an option for long for me, as they'd have the bike more often than it'd be in my garage with my milage!!

Got bored with all the umming and ahhing so have pulled it apart today. Expecting to find something that will be questionable under the warranty route and I would end up paying for it anyway.

Its a nasty job, engine out, and everything disassembled to get the cases split.

The problem;
The bush that second gear sits on on the output shaft, (the gear the other side of the casing to the front chain sprocket) has picked up on the gear and spun on the shaft. This has spun the cir-clip (??) keeping it in place out of its groove allowing the bush to move down the shaft. The clip and bush then got wedged on the shaft and stopped the fork moving along and engaging second gear.
Basically a perfect warranty style issue.

Not got any idea why it went as the oil galleries in the shaft look perfect.
The bike has done alot of high speed running but always take it steady when cold.


Look like a shopping list of torque wrench, output shaft, second gear, bush, clip, gaskets and a few days to put it all back together again.