View Full Version : fell down, went crash, now stuffed
Hello to you all, im sure someone had this issue before and there must be a thread about this ( i did have a search but couldnt find anything), but long story short here its goes:
last saturday went for a ride with some friends had a good time and on the way home was taking left turn maybe a bit faster than i should had to apply brakes and was too generous on front, so lock slide and went down, and broke left rearset clean of the bracket, so few days later i fit new one one and thought hey presto , but no, :( , now looks like i cant change gear and if it changes looks like its almost infinite amount of gears up or down, cant find neutral aswell, so here is the million dollar question, where to start looking for problem, does this means need to take gearbox apart, or there is less difficult procedure i should follow first, (bike starts and runs fine with the clutch in)
Bike is Suzuki SV650s 2001 model (half faired?) only mods ive done myself is new indicators and exhaust but i guess that is irrelevant for this
so please please if anyone can help with good advice it would be greatly appreciated .
Thank You
Chris_SVS
17-08-17, 11:13 AM
Could well be a selector fork broken, I'd be confident that's gearbox surgery to find out
johnnyrod
17-08-17, 11:22 AM
Check the circlip on the shifter shaft, the fat one that goes into the gearbox with the splined end. if you pull it outwards (leftwards - don't worry you can't pull it right out) and look for the groove and its circlip that should be only just outside of the gearbox casing. It might be under a ton of crud. check the circlip is in place, otherwise the shaft can move inwards too far and disengage from the shifter gubbins that sit under the clutch on the right side of the engine. If it's in place then the shaft will have minimal in/out movement as the circlip stops it going inwards. I dropped mine on the left and the circlip popped out, it stayed on the shaft (tight fit) but wasn't doing its job any more.
R1ffR4ff
17-08-17, 11:34 AM
All of the above.I use Partsfiche to help when trying to identify components and their place,
https://www.cmsnl.com/suzuki-sv650-1999-x-usa-e03_model16251/partslist/BLCK0008.html#results
https://www.cmsnl.com/suzuki-sv650-1999-x-usa-e03_model16251/partslist/BLCK0041.html#results
Also the troubleshooting sections in the Manuals can be helpful,
http://i.imgur.com/jCinTnO.jpg
hmm..... tried to pull and push on the shaft that goes in to gearbox with the circlip on, there is only about 1mm movement each way, if you say it can come out it didnt , or i need to pull harder?
johnnyrod
17-08-17, 03:07 PM
Hmm tricky, i would start with the external shifter bits below the clutch. Hopefully as you can't seem to get any gears it's something like that rather than an internal problem. Some more info here
https://forums.sv650.org/showthread.php?t=162162
and here
http://forums.sv650.org/showthread.php?t=95535
with actual pics on page 4 via a link.
if you haven't already then try rocking the bike back/fourth without the engine running and the clutch out while moving the gear lever to get it into neutral. if it wont budge then its more than likely something internal.
have you tightened the bolt on the link onto the spline properly?
With the clutch out can you select a gear and feel drive/a bite?
With the clutch out can you select a gear and feel drive/a bite?
in most cases if you rock the bike back and forth. its how you shift a bike into neutral if the bike wont run or the clutch cable is bust.
Thanks guys, i will try your suggestions tomorrow morning if weather allows, and will keep you posted, working late shifts this week.
good morning, ok this is what i found this morning, after Bibio suggested i did some rocking and rolling and managed to make it stay in gear even with clutch in hmm.... interesting, then more rocking and rolling and managed to find neutral gear, then stuck it in first and back in neutral and back in first, but its not smooth, there is bite and bike moves in gear (only could move couple of feet, decking is not a race track :D), not so long ago i noticed weird sound from what i think is clutch, when changing gear and disengaging clutch being rough it would squeal or squeak (something like that) , and now while engine running tried changing gears and it didnt go in nice, first gear would make bike jump , then tried shifting second and back to first wouldnt go in nice , had to start releasing clutch to put gear in.
So: rocking and rolling managed to do something it would stay in gear with clutch in
then managed to put it back in neutral and few times first and neutral and back again
i think had second and third (just a guess) there was drive
clutch (or something on clutch side of bike) started making weird sound not so long ago
to put in gear needed to start releasing clutch a bit
does this means need to start stripping clutch first?
any suggestions?
sounds like you need to lube and adjust (or replace) the clutch lifter mech or you have a partially seized clutch cable.
Luckypants
18-08-17, 02:12 PM
sounds like you need to lube and adjust (or replace) the clutch lifter mech or you have a partially seized clutch cable.This. The drop may have knocked the adjustment completely out, when it was marginal before.
This post gives a good description of how it is done. http://forums.sv650.org/showthread.php?p=2956356&#post2956356
Search will find many items like this to help you.
johnnyrod
18-08-17, 02:22 PM
Yep, deffo worth a look, the clutch should work fine regardless of which gear you're trying to be in. The gearbox will only change (properly) when it's spinning, so the rocking back and forth simulates this, but it's often not possible to get more than a gear or two away from where you start. The clutch makes no difference to this when the engine's off. All the adjustment is under the front sprocket cover - Sid's description is spot on for how it's done, in the link above.
Regarding the symptoms before, it could also be a dragging clutch. If your bike has done around 20k or more then the plastic worm gear of the clutch lifter is most likely scrap, the little ball bearings dig into it. It'll still work but won't feel great, they're fairly cheap though.
Thanks, I'll try that. Bike has done around 23k.
the wormgear in the lifter is metal. a good blast of degreaser/wd40/chain cleaner etc.etc (you dont need to remove it from the bike) and a repack of grease (pack it in the groove with your finger where you can see a small metal tab) is usually enough to see them working again. dont take it apart as its well fun putting it back together and you might loose some of the tiny bearings. its recommended to use CV/molly grease but any grease will do the job. do not use copper/alloy grease.
i adjust the wormgear screw different to others. turn the lever adjuster out to 1/2-3/4 way first. adjust the screw till it just touches then lock off being careful not to move the screw. adjust bite point of lever by turning lever adjuster back in. nip up the adjuster nut with pliers (they have a habit of working loose). the above does exactly the same as backing of the screw 1/4 turn stated in the manual.
Silly question, so all of this happening on left or right side of the bike?
the clutch lifter is behind the front sprocket cover.
top tip, mark the knuckle of the shifter on the spline with a felt pen line where the gap of the bolt is that way you know where to put the shifter knuckle back on, you need to take the bolt out :-)
there are 3 (8mm socket) bolts to take the cover off, you need a small 8mm 1/4'' drive socket and extension to get them off.
johnnyrod
18-08-17, 06:31 PM
Mcnius, there is a rod that passes right through the engine from the lifter to the clutch. The lifter pushes it in, you'll see the action when you take a look.
Bibs I'm sure the first one I replaced was plastic, I took it to bits to try to grease it but you could see the gouges made by the balls. The second time I replaced it I didn't bother looking - it's a pig to get back together so don't try it. The one on my ye olde GSX250 back in the day was all metal.
You can get the sprocket cover off without taking the lever off the shift rod, it's below not through the cover - progress of a sort! Sometimes they have a dot punched in the end to show you where the split of the knuckle goes, I can't remember this one though.
Oki doki, looks like i will have busy afternoon tomorrow, i will keep you posted guys, really appreciate all your help so far.
OK, First of all i would like to THANK everyone that replied and helped with suggestions, but unfortunately i have to tell you something, Today finally i pulled my finger out of my **** and jumped on Suzi and took her out for a small ride around the block, and guess what, cant find/feel anything wrong (fingers crossed) so i would really like to apologize You all for wasting your time, but it was a good learning curve for me. I feel like a total numpty, now hoping for a bigger ride later in the week and hoping for the best.
So , once again sorry for being such panicky poo and thank you for all your Help :D
great stuff :-)
bike was stuck in a false neutral.
Your guess is better than mine i think, ask me about 50cc two stroke piaggio engines and auto gearboxes i might help you there , but big boys bikes no knowledge what so ever, just noticed that i need to tension my chain up a bit
johnnyrod
21-08-17, 06:55 PM
Glad it's sorted, as Bibs says these things happen, whatever it was has popped back into place. The circlip thing I said about on page 1 - ruined a track day, I thought my gearbox was lunched, had to jack it in after 2 sessions and went home wondering what to do with my bike. Needless to say I was pretty happy when I figured it out, but the bit in between was not at all fun.
Thing is i am very old person trapped in a 32 year olds body, don't like change and if i don't like a sound and feel of something in my car, bike or missus i think i need to fix it or replace it with new stuff, only now slowly im starting to understand that things can be fixed, and sometimes really easily.
johnnyrod
21-08-17, 08:08 PM
TBH you sound more like a youngster, people these days just chuck stuff out or get someone to do jobs for them. I'm a habitual fiddler, always have been. Old stuff is fine if you care for it, you get the odd surprise, and you have to be a bit selective about what you buy/keep. i have a 70 year old camera that works fine and takes great pictures, for example. Old stuff is "vintage" when it's working and "F***** PIECE OF OLD CRAP" when it's not! The SV is a basically reliable axe though.
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