The Day started out great. We got going early and ripped south down hwy 3 at 80 plus. It was an awesome morning. With little wind and we were feeling good about closing in on the final push to Ushaia. We really had no worries.
Then….. I relaize Dan was no long behind me. I pulled over and waited, thinking he must have stopped for a potty break, picture, something… After a while still no Dan. I turned around and headed back about 6 miles to find him on the side of the road. Hands on hips staring at his bike with no sidecases and shaking his head….
I asked him whats up? And looked at his bike… He said – “the f*cking masterlink broke – I was running along at 85 mph and heard a “chabang” – pulled in the clutch and the engine died right off – coasted along looking for a nice place to pull over and listening to the silence and tires whining….. when I pulled over and got a look the chain was still on the bike and there was oil oozing out from behind the countershaft sprocket cover”…
He had spent a few minutes opening every compartment in his bike looking for tools tiill he remembered they were all on John’s bike… so he decided to just relax till John came back.
We pulled the tools from John’s bike and set to work - first we took off the countershaft sprocket cover and saw the chain was super wedged in behind the countershaft sprocket… we tried prying on it, putting the chain on the rear sprocket and trying to rotate the wheel, then putting a little rod we had for leverage on the wheel – then we just sat there and looked at if for a while. John said something like “that’s wedged in there and we’re not going to get it out” – We talked about getting the bike back on the ground and pushing it backwards or something – then Dan said “I’m going to go take apart that fence and grab a fencepost” – about 10 minues later he came back with a steel fence fence post and we stuck it into the rear wheel and used the swingarm for leverage – after 2 or 3 tries we freed the chain from the super wedgy… only to find the chain had fractured the engine case and that was the source of the oil leakage. John said “we’re done dude”. To top it off, Suzuki in their infinite wisdom had placed the clutch actuator shaft/rod right next to the countershaft sprocket – sort of daring the chain to break and blow the rod apart – which, of course, it had.
We talked about it and decided we needed to pull the left engine case cover. But we didn’t have enough oil to refill the engine. We thought about laying the bike on its side but we’d lose the gas out of the tank. So we decided we needed to just lean the bike over far enough to get the case cover off without losing the gas. We took off the left side case, propped the bike on one of it’s own side cases and we used the fence post to hold the rear end up.
Once we got the side case cover off we saw the extent of the damage. The engine case was busted badly, the side case cover was busted and the chain had sheared off some wires. The wires used for the neutral switch and the wires used for the battery charging system…. Of course the clutch actuator rod was blasted apart like a bad guy’s car on the “A Team” TV series.
Looking at the case – it was apparent the pieces couldn’t go back in there cause they were bent too much – even the side case cover had a hole the size of a quarter in it.
We again sat there and talked about it. What did we have, what didn’t we have etc. Dan said “We’re going to fix it and I’m riding it into town on its own power”.
We had some quick steel putty witch is like JB weld. So we set about cleaning the oil and chain spoodge off. Dan mixed up the putty and we built it up as good as we could. This stuff is allot like play dough in that it holds its shape, However when it cures it is like steel. You can file or drill it. While the quick steel cured, we repaired the wires, we had a 12volt soldering iron with us. So those were a pretty easy reapair. After the wires were fixed up,we then filed the putty where the mating surfaces of the cover and case go together. So they were smooth and matched up as well as can be expected. We both were happy with the fit of the cover, So we applied some silicone sealant we had. (Dan had bought some to glue some decorative thingy’s on his bike, good thing too!) Anyway we reinstalled the cover. We had an extra masterlink for the chain so we reinstalled the chain.
Now with the push rod for the clutch smashed into many peices. We had no way to make the clutch work. But thats ok, you can ride without the clutch. In town is pretty tough, but on the hwy no problem. Most bikes shift just fine without the clutch if you do it right. More importantly though, the clutch push rod goes into the engine through a seal. Without the rod the motor will just pump oil out the hole….. We found a small bolt that fit into the hole and we wedged it in place with part of a hacksaw blade and some safety wire…. We test fired the engine and we had NO LEAKS!!!!
Looks as though we were good to go! We loaded all of Dans crap back on the bike and gave him a running push start. He was off and running again…Total repair time about 4 hours on the side of the road.
Every so often John would ride up along side and have a look at the repair area. No leaks. The repair was good. We cruised the 60 miles or so to Rio Gallegos with no trouble.
Dan hit almost every light on the way into town (and ran a few red lights to avoid having to start without a clutch!) and we stopped at the first gas station to fill up and figure out where to go to get a clutch rod ordered/made/cobbled so Dan would have a clutch. While then this dude comes up and starts chatting us up. He knows our bikes are V-stroms so he is a biker. We then tell him about our troubles, needing parts etc. He tells us to follow him and he’ll take us to a bike shop. Cool! so off we go. Dan using the starter button to get going from a stop. He would just have the bike in first gear and hit the button. The starter was strong enough to turn the engine and move the bike forward. Then bingo she would light and off he’d go..
Anyway we got to the bike shop. SM Motos in RIO Gallegos. It didn’t really look like much from the outside and we were a bit skeptical…. But after going inside we saw they had a proper repair shop and more importantly a guy who knew his shit and was willing to help. We pulled the clutch rod from John’s bike and showed it to him. He dropped what he was doing and started searching his shop. He found a rod that was very close. It was a little too big on one end but he set about turning it down on the lathe in the corner. We stood there in disbelief. We had been in his shop for about 30 minutes and he was MAKING a part for us.
It turned out to be a bit more of a job then planned, but in the end we left his shop at 8:30 that night with a working clutch and new chains on both bikes. He charged us about $60 bucks US to make the part and he spent about an hour and half making it…. After closing the shop he then led us to a hotel and wished us luck.
This is the kind of bike shop that most shops in the US have lost sight of. “sure we can order that part, It’ll be here in 2 or 3 weeks. How would you like to pay for that?” If you are ever in Rio Gallegos and need anything for your Moto, Please go spend some money at this place.
BTW my buddy Erik wrote on the very cover that got broken, “Unbreakable top kit” at the going away party… It turned out to be a cruel joke on the side of the road while we were trying to fix it!! Thanks E! We owe you one!
Dan threw down on the best hotel in town after our tough day. We ordered room service, watched a bad movie on TV (Passenger 57 with Wesley Snipes… “Always bet on black” – paaalease…) and talked about how feak’n bad our luck was, As well as how freak’n good our luck was…..
Tomorrow we ride south!!