sv 650 gearbox prob - SV650.org

27-08-07, 03:28 PM

hey everyone, i have just bought a light crash damaged 2002 plate sv 650.
it had minor bodywork scrapes and the footpeg and gearlever had broken off.
the work on the bike has now been done, came to ride it and it is very very difficult to select neutral, the neutral light never comes on, when the engine is off in neutral and the starter is pressed it jumps into gear! also when riding the change from 3rd to 4th is very difficult and not always possible.
it is deffo not clutch drag, does anyone have any experience of this or know what the problem could be?
thanks
steve

fizzwheel · 27-08-07, 07:52 PM

Some things to check

Oil Level
Chain Tension

I found before to much oil and it effects the gear change, as does slack chain.

After that if you're confident your clutch is adjusted properly the other thing to do is take the gear lever off its pivot and give it and the pivot a good clean, theres also a fibre push in the lever that you can gently lift out and and again clean, and then put it all back together with a liberal helping of grease and it should make a a big difference.

I'm not 100% sure of the process of removing the fibre washer, I know you have to be really careful with it and I wasnt brave enough to take mine out, however theres a very good post by Sid Squid on the subject that if you search for you should find and it'll explain the process.

Sid Squid · 28-08-07, 06:56 AM

Adjust the clutch as if it were your life's very purpose.
If there's any question of a sticky lever check for my posts on ensuring that the lever pivot is right.
Even if you think the clutch isn't dragging it may be worth checking for damage on the clutch basket, (plates hanging), this will make gear selection awkward.
Failing that, as it's had a whack on the gear lever, you'll need to see if there's selection problems, you'll already have the clutch cover off so the external parts will be accessible, (if you remove the clutch basket), - lets hope the problem isn't any deeper, selector forks and drum require the motor to be split.

28-08-07, 03:49 PM

its deffo not the lever or clutch basket, both have been checked.
looks like i might have to split the lump.
thanks

31-08-07, 05:33 PM

i have been playing around with the lump and have discovered the source of the prob, the selector drum has small dowels coming out of it and one of these has broken off, can the selector drum be removed or does the lump have to be split?

Spanner Man · 01-09-07, 06:51 AM

Good morning.
The motor will have to be split to remove the selector drum itself, however it looks as though you can remove the selector drum plate with the engine in situ, which is the bit I assume you mean, by removing the bolt in the centre of the selector drum.
Also check the selector claws on the gearchange shaft for any damage, for it would have been one of those that snapped the dowel off in the first instance.

Cheers.

Richie · 01-09-07, 08:42 AM

You'll have to split the lump... as spanner man say, sounds as if the bike was dropped on the gearchange side and that has caused all the internal damage.
Whilst it's apart it a good time to check all the other things you need to check for a full engine service.

Richie · 01-09-07, 10:58 AM

Give Northwind a PM as I got his gearbox but he still got the selector drum for the Curvy engine...
hope you get your problem sorted out.

northwind · 01-09-07, 12:02 PM

Yeah, I should have a spare somewhere, but I'm none too sure what I did with it... I'll have a look, if you want it.

02-09-07, 02:36 PM

so if its just the drum on the end it can be replaced with the engine in situ?
is the bolt recessed in the center if the drum??

27-08-07, 03:28 PM	#1
stevenford_uk Guest Posts: n/a	sv 650 gearbox prob hey everyone, i have just bought a light crash damaged 2002 plate sv 650. it had minor bodywork scrapes and the footpeg and gearlever had broken off. the work on the bike has now been done, came to ride it and it is very very difficult to select neutral, the neutral light never comes on, when the engine is off in neutral and the starter is pressed it jumps into gear! also when riding the change from 3rd to 4th is very difficult and not always possible. it is deffo not clutch drag, does anyone have any experience of this or know what the problem could be? thanks steve

27-08-07, 07:52 PM	#2
fizzwheel Super Moderator Mega Poster Join Date: Dec 2003 Location: Somerset Posts: 3,614	Re: sv 650 gearbox prob Some things to check Oil Level Chain Tension I found before to much oil and it effects the gear change, as does slack chain. After that if you're confident your clutch is adjusted properly the other thing to do is take the gear lever off its pivot and give it and the pivot a good clean, theres also a fibre push in the lever that you can gently lift out and and again clean, and then put it all back together with a liberal helping of grease and it should make a a big difference. I'm not 100% sure of the process of removing the fibre washer, I know you have to be really careful with it and I wasnt brave enough to take mine out, however theres a very good post by Sid Squid on the subject that if you search for you should find and it'll explain the process. __________________ Look Dave, I can see you're really upset about this. I honestly think you ought to sit down calmly, take a stress pill, and think things over. K5 GSXR 750 Anniversary Edition

28-08-07, 06:56 AM	#3
Sid Squid No, I don't lend tools. Mega Poster Join Date: Jul 2003 Location: Skunk Works, Nth London Posts: 8,680	Re: sv 650 gearbox prob Adjust the clutch as if it were your life's very purpose. If there's any question of a sticky lever check for my posts on ensuring that the lever pivot is right. Even if you think the clutch isn't dragging it may be worth checking for damage on the clutch basket, (plates hanging), this will make gear selection awkward. Failing that, as it's had a whack on the gear lever, you'll need to see if there's selection problems, you'll already have the clutch cover off so the external parts will be accessible, (if you remove the clutch basket), - lets hope the problem isn't any deeper, selector forks and drum require the motor to be split. __________________ If an SV650 has a flat tyre in the forest and no-one is there to blow it up, how long will it be 'til someone posts that the reg/rec is duff and the world will end unless a CBR unit is fitted? A little bit of knowledge = a dangerous thing. "a deathless anthem of nuclear-strength romantic angst"

28-08-07, 03:49 PM	#4
stevenford_uk Guest Posts: n/a	Re: sv 650 gearbox prob its deffo not the lever or clutch basket, both have been checked. looks like i might have to split the lump. thanks

31-08-07, 05:33 PM	#5
stevenford_uk Guest Posts: n/a	Re: sv 650 gearbox prob i have been playing around with the lump and have discovered the source of the prob, the selector drum has small dowels coming out of it and one of these has broken off, can the selector drum be removed or does the lump have to be split?

01-09-07, 06:51 AM	#6
Spanner Man Member Mega Poster Join Date: May 2005 Location: Sunbury Middlesex Posts: 1,396	Re: sv 650 gearbox prob Good morning. The motor will have to be split to remove the selector drum itself, however it looks as though you can remove the selector drum plate with the engine in situ, which is the bit I assume you mean, by removing the bolt in the centre of the selector drum. Also check the selector claws on the gearchange shaft for any damage, for it would have been one of those that snapped the dowel off in the first instance. Cheers. __________________ Spanner Man http://stewarts-motorcycles.co.uk/default.html

01-09-07, 08:42 AM	#7
Richie fantabulas Mega Poster Join Date: Apr 2004 Location: Nr Durham Posts: 4,940	Re: sv 650 gearbox prob You'll have to split the lump... as spanner man say, sounds as if the bike was dropped on the gearchange side and that has caused all the internal damage. Whilst it's apart it a good time to check all the other things you need to check for a full engine service. __________________ My Flickr photos Last edited by Richie; 01-09-07 at 08:46 AM.

01-09-07, 10:58 AM	#8
Richie fantabulas Mega Poster Join Date: Apr 2004 Location: Nr Durham Posts: 4,940	Re: sv 650 gearbox prob Give Northwind a PM as I got his gearbox but he still got the selector drum for the Curvy engine... hope you get your problem sorted out. __________________ My Flickr photos

01-09-07, 12:02 PM	#9
northwind Moderator Mega Poster Join Date: Jan 2004 Location: In the garage where I belong Posts: 17,082	Re: sv 650 gearbox prob Yeah, I should have a spare somewhere, but I'm none too sure what I did with it... I'll have a look, if you want it. __________________ "We are the angry mob, we read the papers every day We like what we like, we hate what we hate But we're oh so easily swayed"

02-09-07, 02:36 PM	#10
stevenford_uk Guest Posts: n/a	Re: sv 650 gearbox prob so if its just the drum on the end it can be replaced with the engine in situ? is the bolt recessed in the center if the drum??

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