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Posts posted by RayBoy
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15 hours ago, Gwbarm said:
I was thinking that also, being twisted, but its hard to tell, it could be camera distortion.
I don’t see any links to eBay.
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8 hours ago, Mech said:
Yeah there's something wrong in there.. The forks have a bit built up on their ends so they only contact the gears at opposite sides of the diameter, so the gear will slide nicely. If we tried to slide a gear along by pushing only on one side of it, it would try and jamb on the shaft and not slide. That fork that's touching the gear up in it's arch, shouldn't be.
That fork may be twisted.. the wear looks worse on one arm of the fork.. Where's that eagle eyed Parms..
I replaced the forks after the first time the roller broke. Do you think it would become twisted AFTER it was installed? I’m not sure if the damage happened before or after the roller broke.
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14 hours ago, Mech said:
That's weird.. In fifty years of working on hundreds of bikes I've only ever seen a couple of those broken. Two is not right.
Well.. I'd guess the roller should be virtually unbreakable in that situation, if it fitted nicely on the pin. The pin would support it fom being distorted no matter how chattery or loose in the shift barrel. The pin is the only thing I can see being the cause.
That said.. are those shift forks blue on their ends !! ? And they are normally built up width ways so only the end of the fork touches the gear. That top gear looks like it's been touching the gear in the arched part of it. None of that should really cause the roller to break, but it does look like there is some end float or thrust issue going on there..
The shift forks don’t appear to be blue on the ends.
There was noise coming from the motor in high and low range use and I’m not sure if the fork damage came as a result of the broken roller or if it was damaged along with the roller. I suspect if the fork was being damaged for 5 years, it would looks a lot worse.
After the first time this happened about 4-5 years ago, I replaced both forks (which I’m doing again).
Do you think there’s a problem with the shift drum? I’m kinda baffled
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Hey all,
I’m having a problem trying to solve why my shift fork roller keeps breaking. I have a 2009 Suzuki King Quad 500 and now, for the second time, one of the shift fork rollers has broken and was causing some transfer issues. Again, this is the second time this has happened. I can’t figure out why this would be a recurring problem. It happened about 4 years ago. Do the forks rattle in the case enough to eventually break? The quad doesn’t get a ton of hard use. Yard work and snow removal in the winter. I thought it may be because I’ve been pushing snow in high range 4x4 but would that break a roller?
I would sure appreciate any help.
Thanks
Ray from SK
2009 KingQuad 500 Shift forks roller breakage
in Suzuki ATV Forum
Posted · Edited by RayBoy
I’m not sure if that damage on the fork happens as a result of the broken roller or caused the broken roller. I am missing a spacer shown below. Number 19 in this pic. It’s a spacer/lock washer so maybe that the problem?
I sure appreciate the help here. I’ll assemble things as you suggested but I’m thinking my problem could com from a missing spacer.