Re: Not selecting neutral when stopped
 

I've tried adjusting it and that seems to have helped a bit, I've spent about an hour trying all sorts of different positions and it's still not right though... Also there's more play in the adjuster than I previously thought, looks like I may need to replace the worm gear then :/

Atassiedevil: I can get second with a blip of throttle then I can get neutral from there with another blip of throttle. It's still pretty tough to get it up into second though, i have to force it :S

Re: Not selecting neutral when stopped
 

Is your idle speed set right (c.1200-1300rpm from memory)? Too low can cause difficulties selecting neutral. Perhaps try tweaking it up to see if it makes a difference?

I presume changing gear whilst riding is OK?

Re: Not selecting neutral when stopped
 

It may be a tad low but i couldn't really say, I only got the bike very recently and I had a ZXR400 before and it's quite hard to compare the 2 :P
Changing up whilst riding is fine but for the down shifts i have to match the engine speed to the road speed to get it to change, as if I was riding without the clutch almost...

I've been looking at replacement worm gears. And I noticed something, the rubber spacer/buffer (or whatever the proper name for it is) at the base of the gear where it meets the arm seems to be very warn compared to how it was on a brand new kne that I saw. Could that possibly be what's causing the problem? I was thinking about trying to replace the piece of rubber and seeing if that makes a difference

Re: Not selecting neutral when stopped
 

I had exactly the same problem as you and it developed in the same way Sid Squid describes.

I put off sorting for ages and kept readjusting to stop it dragging without slipping but one of these:

http://www.ebay.co.uk/itm/05-Suzuki-...-/181244733422

- and 20 mins to fit is all it took to put right.

Re: Not selecting neutral when stopped
 

I'll replace it if i can't get it to work with more adjustments. I've found a replacement that's £10 but it's off a K5, does anyone know if that'll fit the '02 model? :S I also want to know whether the rubber at the back being worn will be making a difference, cos if it does I might try repacing the rubber and see if that solves it or at least helps (the one on mine seems pretty worn compared to how it should be new...)

Re: Not selecting neutral when stopped
 

If it's knackered it knackered - the rubber won't matter, and the fact that it needs such faff to get the adjustment right means it's clearly worn - replace it.

K5 lifter fits fine.

Re: Not selecting neutral when stopped
 

Ok, thanks very much! :)

Re: Not selecting neutral when stopped
 

That one was on ebay and someone else bought it... Now the only ones I can find are from america and they're a lot more expensive, they'll take ages to turn up and I'd run the risk of getting hit with import charges too... :( I know you're not meant to get charged for second hand things but I'd rather not risk it and just buy one from the UK :P

Re: Not selecting neutral when stopped
 

why bugger about with secondhand parts,buy the part new,the CLUTCH RELEASE SCREW ASSY is only £45.50 from robinsons,and no doudt about the same price from your local suzuki dealer

Re: Not selecting neutral when stopped
 

I don't have much money atm so as it stands I can only afford a second hand replacement, if the replacement wears out too then I'll replace it with a new one if I can afford it at the time