Please ignore my previous major post, it was complete Bollocks
Embarrassingly I had everything Arse about Face.
Something just wasnít making sense to me, and I wasnít comfortable with what I was doing, so I went back to first principles.
Very significantly this was partly because I was missing Reverse gear, yet the dog clutch for reverse looked a lot better than the Forward gear end.
This time I took more notice of the description of the Ďnew for 1991í gearbox internals in the genuine Suzuki manual I have.
The penny dropped when I found one line of text. This line states that Ďa new Counter Rotating gearbox was developed for 1991í, there is then 12 pages of detail without the counter rotating bit being mentioned. -
So basically Browns Point website was correct, and Iíve been running a counter rotating gearbox in reverse with a standard prop for the last few years. The mistake probably happened as I changed the control lever at the same time as the gearbox, and worked backwards from the Prop to decide which way to assemble the insides of the control box.
The reverse gear internals of the CR box are the same as those for forward on the std box, and the forward gear internals are beefed up versions of the std reverse, the differences include extra thrust bearings, bigger shaft sizes and a different Dog Clutch shifter because of the shaft size.
The Dog Clutch Shifter is stronger for the CR Forward than CR reverse, so Iíve been lucky itís lasted, but it is concentric about its middle, so I can just turn it 180degs and will end up with a box which is as strong, if not stronger, as a std box in what Iím using as forward, but stronger than a std box in what Iím using as reverse.
It also explains why the Dog Clutch was damaged, as the bigger dogs donít have as much room to drop into mesh when Iím crashing into reverse.
However Iíve been trying to order the unique to the CR gearbox Dog Clutch Shifter.
From a brief internet search I discovered two US distributers who list the part, and have quoted delivery from the US to my door in the UK in @5-7days for a total cost of @£90.
I contacted 3 local dealers, they could not find the part number, and so did not want to help. One did agree that they could not find a parts list for the counter rotating gearbox, and that ďit must be on thereĒ. Having waited 3 days for them to contact Suzuki UK I decided to contact a dealer further afield for help.
have been very helpful, however they are now being held up by Suzuki UKs apathy
They too could not find the part Number, but like me found it on the Browns Point Suzuki website, so contacted Suzuki UK on my behalf to enquire about sourcing it.
They and I were surprised by the reaction they received.
They were told the part was not on the Suzuki UK system, but it could be added, this would take 1 week, and only then would they be able to order it. They were then given a price of £200 to pass on to me.
Obviously Iím going to be placing an order with Browns point later tonight, and Iíve sent Suzuki UK a snotty email.
In the mean time Iíve cleaned everything up and made a special tool to wind the retaining ring back in.
I did consider machining the old Dog Clutch Shifter, but realised Iíd have to be really accurate, and itís probably case hardened anyway.
More to come