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Old 16-05-20, 09:52 AM   #1
proze
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Default Gear shift problems - confusion

Hi all. I've had my naked SV for two-and-a-half years. Commuting and trackdays. It hasn't skipped a beat. For context, I did have a highside at Bedford in 2018, which snapped the right-hand footrest and damaged my exhaust. The left side was okay.

At some stage, and I don't think it was immediately after the crash, the gear shifting went 'crunchy'. Like shifts wouldn't be one solid 'clonk', there'd be a secondary movement or grittiness after the nice, positive shift.

So today I took out the clutch so I could have a look at the mechanism and shaft (the clutch was amazing after 18k miles). But looking at the mechanism:
  • There's some strange scoring on the bolt that holds in the shift-star.
  • The shift 'fork' thing is sprung and can wiggle, marked B in the picture attached.
  • It seems to me that it can catch the posts on the shift-star, marked A on the picture.
  • If I move the fork manually and it catches those posts, it feels a lot to me like the crunchiness I feel in the lever with my foot.
  • Only the pink area is meant to push the post, but the green area can catch the top of the previous post. There's some evidence that this has been happening, looking at the top of the posts (the cyan marked bit).
  • The shift shaft has about 0.5mm play in the through-the-bike direction.

Does any of my description make sense? Does it sound like a problem anyone here is familiar with? Is the problem or solution obvious to anyone?

Many thanks!

Edit: Sorry, I can't get these pictures uploaded at all. Please have a look here: https://imgur.com/a/sCrZmIb

Last edited by proze; 16-05-20 at 09:59 AM.
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Old 16-05-20, 11:44 AM   #2
garynortheast
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Default Re: Gear shift problems - confusion






Just put the image address in img tags to show the pictures.
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Old 16-05-20, 12:30 PM   #3
proze
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Default Re: Gear shift problems - confusion

Thank you!
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Old 16-05-20, 01:32 PM   #4
SV650rules
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Default Re: Gear shift problems - confusion

Have a look at this video.

https://youtu.be/Myy8bklmH70
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Old 16-05-20, 02:41 PM   #5
proze
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Default Re: Gear shift problems - confusion

Thank you, I found that a while ago. His solution was to replace everything! Which is spendy. I'd really love to know what's wrong before I go that route.
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Old 16-05-20, 04:26 PM   #6
proze
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Default Re: Gear shift problems - confusion

I have a theory. I took the sprung shift-star cam stop off and rotated the crank by hand and all the gears select perfectly turning the shift star. I put the sprung cam stop back on and still, all the gears select perfectly. The shift star looks perfect, besides a few marks on the posts.

So I was looking at the shaft and fork/plate thing, as an assembly. And I saw that it wasn't parallel.



And this would cause the green section in the pictues above to foul the posts, I think.

So I took the circlip and spring and fork off the shaft. And, have a look, the boss on the shaft plate against which the fork is pushed is worn on both sides. Which would explain why the fork is not square to the star anymore.




As an aside, the shaft is also worn where the fork rotates about it:




What do you think, SV people? Might this be the issue?

Anyway, I'm going to look for an M8 0.5mm stainless washer that I could slip in there.

Last edited by proze; 16-05-20 at 04:33 PM.
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