New Owner / need some help

[CPKID]

Hi Fellow Rotary bikers,
Not to long ago I purchased a 76 RE5 in good shape. It had been sitting for quite some time . I did my homework and followed all suggestions from previous posts. I changed all fluids, Put WD 40 in the spark plug hole , took apart carb ( twice ) cleaned every jet and all linkages Check rotary tip oil flow . Replaced air filter and cleaned out hose and filter box. Purchased new lawn tractor battery . Used a fuel mix initially .
We were able to start engine and after pulling and cleaning carb the second time it ran great . All systems were go . Although I have a big concern !
Second gear chatters something awful . First gear is fine and third gear is good . Second gear rattles and grinds something awful . The engine runs smooth as silk . I'm upset about it . My brother says we might be able to pull transmission gearing without taking engine out . Please advise .
One other issue . Rectifier plug white/black wire goes to solid green on other side . Is the solid green going to ground ? It's stripped and unattached on my bike .
Any help would be appreciated .
Regards,
CPKID

[Jess]

Proper unit must come out to get into the transmisson...

Sorry...

Best Regards,

[bdalameda]

I seem to remember removing an RE5 transmission without removing the proper unit. Had to remove the clutch and take the engine mounts loose and lift the engine enough to remove the transmission case over the frame engine mount tab. This was 35 years ago so I could be wrong.

[wayne]

I was musing about this myself a year ago. I pulled the whole engine out. I think that it may be possible Dan but having done one recently, it would be extremely fiddly to reassemble in situ.

I think that the most practical and guaranteed way to do it is as Jess states.

[bdalameda]

The proper unit can stay attached to the main case. I am sure it probably would be just as easy to remove the entire engine to get at the transmission case.

[CPKID]

I thought as much . I just bought a 76 transmission on eBay . Now we know why the bike sat so long with low mileage. I'll be able to give it a proper cleaning now . Compression was over 120 by the way .

Can anyone provide a schematic to ID my wiring question from rectifier ? Thanks for all help . I will keep you posted .
Jess.... I will be in touch . I will have engine out so there might be other things I can do in a preventive measure. I was about to send you the carb , but on second attempt ( pulled carb twice ) got bike running great. With the first test drive we noticed second gear issue .
Regards,
CPKID

[mike500]

you can download the wiring diagram from tonny's site www.suzukire5.dk/index_eng.html its in the technical section regards mike

[CPKID]

If the gearing won't quiet down after riding it again we will investigate 2nd gear issue. If I can get at it without complete pull . I certainly will do that . I will keep you posted and take pictures for everyone's reference . Thanks for all the help . Interesting motor ....I love this stuff .
Always remember that with enough parts and time you can fix anything .

Regards,
CPKID

[goandy]

Check with Jess or ebay- nos gears come up regularly if you need new ones.

[redbug2]

Worked with my brother cpkid on the re5 referenced on this thread. Rode it around some more to see if skipping would go away. It could take power on second but would skip. I said it was a bad gear so we decided to tear it down. It took about 4 hours to remove the engine. Hung the starter off to the side. Removed all fluids. Took carb and intake manifold off. Took throttle cables off at handlebars and slipped them off with engine.

Removed right casing and took transmission casing off. Looked at the transmission and it looked great. I felt awful because I thought I had miss-diagnosed the issue. Started turning the gears around slowly and bingo! Missing tooth on second gear. See link below. That's not rust on the gears, its dirt from my glove. Not very sterile at that point....

www.cyclerestorer.com/pages/restoration_pics_view.php?bef_aft_row=101&td_var=4

Had good transmission from my next project bike and put that in. Reassembly took a lot longer than removing. Partly because we decided to clean the engine and replace all of the tubing. Also ignition timing took a little bit of trial and error. Manual static timing was a little different than the spark method on this forum. Finally after two removals of the right casing were were able to get the timing right. Also had to tap out one stud on exhaust manifold.

Shifting through all gears fine now and its running a little better.

I'm not sure we could have removed the transmission while in the frame.. Maybe its possible but by the time you remove all of the mounting hardware to tilt the engine you might as well pull it out. Plus, putting all the gears/shifting forks/springs/etc would be very difficult around the frame.

Still sputtering at times. I guess we have the classic flat spot. Going to have my brother ride it around some before we commence with the fine tuning. It's running better every time I ride it. But I'm only driving up and down my driveway. I would like to see 3 to 4 gallons of fuel go through it first.

Here's a video of me driving it up and down the down the driveway. Every once in a while it sputters. (video and audio seem to be out of sync)





Regards,

Redbug2