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Gearbox woes

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Blue_SV650S
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Joined: 27 Nov 2008
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PostPosted: 18:11 - 29 Nov 2016    Post subject: Gearbox woes Reply with quote

Rode the bike as normal, parked up. Got back on the bike, started and rode off, but the gearbox only selects 1st, 2nd and neutral as normal, it refused to go into 3rd (or higher obviously), the gear leaver was acting as if I had hit 6th i.e. I get a solid leaver as if I am at the top of the gearbox.

No horrible noises, no missing gears, just refuses to go higher than 2nd.

Ideas?
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G
The Voice of Reason



Joined: 02 Feb 2002
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PostPosted: 18:27 - 29 Nov 2016    Post subject: Re: Gearbox woes Reply with quote

What bike?

Does it have a linkage?

I had pretty much the same on a J zx6r which turned out to be a dirty linkage.

Changed find by hand on a paddock stand, but felt like you describe riding.

Very odd. Few sprays of WD40 and it was fine.
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Blue_SV650S
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PostPosted: 19:22 - 29 Nov 2016    Post subject: Reply with quote

The old SV650

It was not like the gear was hard to find, it was 'solid' and not going up - but 1st, neutral and 2nd worked perfectly normally with no horrible feel or noises. Clearly if I can move the leaver from 1st to 2nd there is no leaver reason why I shouldn't be able to get 3rd and above.

I did leave a bit of info out to see what people had to say first ... I removed the leaver and linkages so I could get some mole-grips on the gear-change shaft; same symptoms. So it deffo wasn't worn linkage problem.

The final bit of information is that I put the bike on a paddock stand, selected 2nd gear and bounced/forced/span the rear wheel back and forth rapidly by hand whilst applying a rude amount of pressure back and forth on the mole-grips and it eventually went into 3rd (and above).

All gears are now selectable but gotta say I am nervous to ride it! (did test ride slowly round the block, but I mean continue to ride it as before).
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G
The Voice of Reason



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PostPosted: 20:09 - 29 Nov 2016    Post subject: Reply with quote

Ah well.

Mine did feel like that - really weird as it was just from dirty linkages.

Well, think I've got a curvey SV650 engine for sale if it's all gone horribly wrong! Razz
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Blue_SV650S
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PostPosted: 21:13 - 29 Nov 2016    Post subject: Reply with quote

My concern is that if it goes 'horribly wrong' when whatever it was rears its head again in a more sinister way than just refusing to select gears i.e. the gearbox locks up solid on me at speed/inopportune moment! Pale
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Pete.
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PostPosted: 21:45 - 29 Nov 2016    Post subject: Reply with quote

These are the bits that make the shift drum turn:

https://www.robinsonsfoundry.co.uk/shop/online-store/suzuki-parts-finder/sv/sv650/x-y-k1-k2-1999-2002.htm#!sv650xgearshift

First thing I would do is pull the clutch cover and see how much of it is visible. Check the cam plate is not coming loose and the condition of the pawl hooks and pins. Operate the gear change and watch for anything unusual. Pay particular attention to the 2nd-3rd shift, is the drum trying to turn slightly under the lever operation or is it stuck solid?
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RhynoCZ
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PostPosted: 21:53 - 29 Nov 2016    Post subject: Reply with quote

When was the last time you changed the oil? Sometimes, fresh oil helps with gearbox issues.
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Paddy Blake
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PostPosted: 22:45 - 29 Nov 2016    Post subject: Reply with quote

If you do need to take it apart file down the shaft you put the
mole-grips on or it will reck the seal.

My guess would be selector drum and lack of oil change.
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Blue_SV650S
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PostPosted: 14:32 - 30 Nov 2016    Post subject: Reply with quote

Pete. wrote:
These are the bits that make the shift drum turn:

https://www.robinsonsfoundry.co.uk/shop/online-store/suzuki-parts-finder/sv/sv650/x-y-k1-k2-1999-2002.htm#!sv650xgearshift

First thing I would do is pull the clutch cover and see how much of it is visible. Check the cam plate is not coming loose and the condition of the pawl hooks and pins. Operate the gear change and watch for anything unusual. Pay particular attention to the 2nd-3rd shift, is the drum trying to turn slightly under the lever operation or is it stuck solid?


Sadly everything I might want to get to sits behind the clutch basket, so it would need the side casing off and clutch basket out. Also where it is working now, I am not sure there will be anything to see.

All that said, if I am to gain confidence in it again, then I'll need to have a look to assure myself there is nothing obviously wrong in there.

Or just ride it and stop being such a worry wuss! Very Happy
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