View Full Version : Very hard to change gears
humillard
08-04-09, 08:49 AM
Hi
I have a 1999 SV650S 19k miles.
Yesterday I was riding home from my daily commute and suddenly my gears became very difficult to select up or down. I managed to travel the last two miles to home. Got out the Haynes manual and set about trying to make a difference with my clutch adjustments. To no avail.
I adjusted the clutch to where it would start to bite at just over halve way out and when the clutch was fully in the bike would roll freely. However I still couldn't get any gears not even neutral with the engine running. However, when I switched the engine off, I could feel 1st N and 2nd easily.
The clutch was replaced less than 2000 miles ago along with a new cable. The 18000 mile service, which I didn't ask for, was done during the MOT, included an oil change less than 1000 miles ago 10 Feb.
I checked the Haynes manual Trouble Shooting guide which claimed it could be just about anything. It wasn't very specific to symptoms.
I checked the linkage the splines and that what I could see without taking the bike apart seem to be fine, plus like I said with the engine off it selects them fine.
Is this going to be expensive to get fixed? I love the poke the SV has but the S version handlebars are tiresome, yet I like the fairing. Wonder if it's time to limp it to the shop and trade it in. But I just had the clutch, heated grips and new aluminium cover put on. Hmmm any advise is welcome.
Welcome to the forum.
Check you oil level isnt too high, somewhere between the full and empty mark.
Check your clutch adjustment is correct.
Check that all the components are working as they should.
Check the linkage from pedal to the gearbox and that it returns smoothly (Sometimes the pedal deos not return to where it should, the washer/gromit get corrosion underneath it and stops it form moving freely)
If all is well, then i would check the clutch itself and that all is tight and happy.
Where are you based, maybe someone can have a look at it for you, me if you are local to Bromley/Beckenham
humillard
08-04-09, 09:15 AM
I live in Ealing, London. I checked the oil on the weekend and it was bang in the middle. As mentioned, I did check the clutch adjustments, I just had the clutch changed by the dealer (as if that will make it any less likely to not be the clutch :))
Haynes manual mentioned gear changing bearings and drums also bent forks or rods if dropped but it hasn't had and abuse since I've owned it (Sept 08). Just daily commute and pampered on weekends.
dizzyblonde
08-04-09, 09:25 AM
If you take the plastic sprocket cover off on the side next to your gear lever, you'll find all the parts that tend to get gummed up. Trust me, theres a lot of road muck that gets mixed up with the oil flung off the front sprocket in there, and its all nicely made up into a giant ball of black splodge on the bits that hide behind the cover.
Its worth a look behind it.
humillard
08-04-09, 09:31 AM
Thanks dizzyblonde, had that off when adjusting the clutch, you were right full of yuk stuck to the plastic, but not obstructing anything, but removed it anyway.
Take the rearset's apart, clean them of all the road muck and salt and sh!te, grease them, and put them back together..
Where the gear lever is connected to the footpeg, need to take that apart and do as mentioned above...
Is it like stiff to change down?
But changing up isn't as bad?
David.
dizzyblonde
08-04-09, 09:32 AM
when was the last time you changed your oil?
edit...1000 miles ago..duh!
The Guru
08-04-09, 09:43 AM
... I just had the clutch changed by the dealer (as if that will make it any less likely to not be the clutch :))
...
Take it back to them..
SoulKiss
08-04-09, 09:59 AM
I live in Ealing, London. I checked the oil on the weekend and it was bang in the middle. As mentioned, I did check the clutch adjustments, I just had the clutch changed by the dealer (as if that will make it any less likely to not be the clutch :))
Haynes manual mentioned gear changing bearings and drums also bent forks or rods if dropped but it hasn't had and abuse since I've owned it (Sept 08). Just daily commute and pampered on weekends.
Pop down to Soho on Friday, there may be someone there who can at least have a look and advise....
vardypeeps
08-04-09, 12:30 PM
Have you checked your chain too?
Have you checked your chain too?ooo, if rogot about that. Your chain should have at least an inch of play with you sitting on the bike. A fellow orger came round the other day and his chain was tight as anything with no play and that was a little difficult changing gear!
humillard
08-04-09, 12:55 PM
Yes the chain is fine, I'll try and limp it to the Suzuki dealer that fitted the clutch. I'll try WD40 on the linkage before I set-out. I'll let everyone know what they find, hope its worth the expense.
Try to loosen up the linkage(thats the word i forgot :() from the outside, if that helps slightly, it would be worth taking apart, cleaning and greasing it.
Be careful with the nylon bush around it, very easily broken :(
If you try to move you're gear lever, does it feel still and lacks movement?
Also, is it harder to change down compared to changing up??
humillard
08-04-09, 02:55 PM
Well it looks like its the clutch, the mechanic thinks it might have lost a bearing. They didn't have time to take the clutch apart, so it is booked in for next Thursday and I had a IAM lesson booked for next Wednesday :( guess I could take my Intruder M800 but it just wouldn't be as fun. I'll post what they find.
SoulKiss
08-04-09, 03:01 PM
Well it looks like its the clutch, the mechanic thinks it might have lost a bearing. They didn't have time to take the clutch apart, so it is booked in for next Thursday and I had a IAM lesson booked for next Wednesday :( guess I could take my Intruder M800 but it just wouldn't be as fun. I'll post what they find.
You expect to have fun with the IAM......................
oh dear :p
timwilky
08-04-09, 03:10 PM
The usual suspect is the pivot point of the gear lever. the inside of the lever where it rotates corrodes and restricts free movement.
remove it and very carefully remove the brittle split bush. pull it in to reduce the diameter gently to remove it. polish up the bore, a little grease to prevent further corrosion and reassemble the split bush and back onto the peg.
hmmm sorry i cant help but a friend of mine has just bought a 125 and it has the same problem. be good to know what causes it so i could let him know
You expect to have fun with the IAM......................
oh dear :p
And why not?
Don't mock it 'til you try it.
humillard
25-04-09, 08:26 AM
hmmm sorry i cant help but a friend of mine has just bought a 125 and it has the same problem. be good to know what causes it so i could let him know
Several visits later and its still not fixed, not that I think the issue is that difficult to diagnose, they just didn't write anything down and didn't remember previous conversations of how/when the symptoms were generated and lack of organisation.
They took the clutch out and are now saying the clutch baskets are worn and causing the problem, clutch baskets aren't replaced when a clutch is replaced. Its booked in for next week. Its looking like it will cost around £300. I'll let you know if it fixes it.
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