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The motor and trans do not come apart to replace the pull cord, just remove the cap and rewind the spool then replace the cord. Not a lot of disassembly required, just a couple of small bolts.
This engine transmission setup is the same as the Suzuki SV DL 650. the engine needs to be removed from the bike and placed on a workbench and completly disassembled. If your good at this kind of work and have lots of experience and have a good workshop and helpers used to doing motorcycle or car transmission work you canpossibly do the work your self. You might look at the break downs of the transmission on Bikebandit.com just ot see what the parts look like and to also see if the parts you think your going to need can be bought. It's possible that replacement parts will have to be ordered and then made and they may have a very high price. Do not take the bike apart till you know that you can get the replacement parts and or the dealer says they can fix anything in this area. If you take it apart you will have to put it back together agian fixed or not or even the dealer might not offer to fix it. these engines if left disassembled even for a few days tend to lose bolts or parts and you tend to forget how it goes together. So if you do that it apart and see what you need to fix it and you can't get the parts the same day ( most of the time with a motorcycle) You need to pu it all back together as to not lose anything or get dirt in it where you might not be able to get it out.
It shouldn't take more than a couple of hours, 3 or 4 at the most, to disassemble the transmission. Sounds a bit expensive for just taking it apart. I would check some other places.
Unless you have a Moto Guzzi, BMW,a Honda CX500, or a bike with a transmission separate from the motor. You will have to remove the motor and split the engine cases to fix the damaged transmission parts. In other words in most cases a complete disassembly of the motor will be necessary.
The only way to repair it will be to remove the transmission and tear it down to see what broke. I have the same transmission in one of my vehicles (4L60E) and had the exact problem, 1st and 2nd, no 3rd gear. It turned out the 3-4 clutch pack was burnt up and had to be replaced. The labor involved with removing and disassembling the transmission is so great that it makes sense to rebuild the transmission, not just replace what is broken. So i would say it's time for a transmission rebuild or purchasing a crate transmission from someone like jasper.
Unfortunately, this most likely means that you've got worn or damaged parts inside the transmission - which also means that the engine has to be removed and disassembled.
With the transmission parts removed, check for rounded edges on the gear "dogs". Having straight edges on the dogs is what keeps the gears from sliding apart and the transmission from jumping out of gear when power is applied.
Also check the shift forks for wear and straightness. When your transmission jumps out of gear, excess force is applied to the shift forks, causing wear and sometimes bending.
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