Clunky Box: Reason and Remedy
 

After changing oil, filters, spark plugs, chain and sprokets (again!) on the weekend, I have noticed it is near enough impossible to change gears without the gear box clunking into gear.
It is fixed by not using the clutch going up gears, but this isnt the easiest thing to do when filtering through London traffic as the revs arent high enough for it to change smoothly.

What do you think the cause of this problem is? At first I thought the clutch might be on the way out, but then it has only got 23,000 on the clock so it should still be ok... shouldnt it?

Knowing my luck it is probably on its last legs and will need replacing.

Re: Clunky Box: Reason and Remedy
 

You had to take the clutch actuator mechanism of to get to the front sprocket. Did you adjust that or maybe not do the two bolts up tightly?

Re: Clunky Box: Reason and Remedy
 

how long have you been doing clutchless changes that could be the problem the standed clutch is not meant for it you can buy them from most race shops

Re: Clunky Box: Reason and Remedy
 

I didnt adjust it, i just took it off, changed the sproket and put it back. I will check the bolts tonight, one of them might have come loose... hopefully.

I useually dont change without the clutch, but it got so annoying that I had to.

Is it easy to replace the clutch if needed?

Re: Clunky Box: Reason and Remedy
 

Checked chain tension and clutch cable tension?

Sometimes my gearbox is clunky when its all a bit cold, gets better after 15 mins of riding though

Matt

Re: Clunky Box: Reason and Remedy
 

you may only have to change the plates unless the basket is knotched up should be simple to change with the right tools and a manual

Re: Clunky Box: Reason and Remedy
 

I would be surprised if it's the clutch unit at that mileage. Quite easy job, although you've got a pointy? Not as easy as curvy. not that I've done one mind you.

Re: Clunky Box: Reason and Remedy
 

Im more concerned that you've changed the chain and sprockets twice or is it 3 times in 23000 miles!!!

Get yourself a scotoiler!!

AS for the box. What would you define as clonky? My gear change has never been what i would call smooth, but after 53k my box is certianly becoming a pain. (Jumps out of gear, hard to engage)

Make sure your clutch is adjusted properly (Search for it by sidsquid) Make sure the selctor bar where it goes into the engine (There is a washer and circlip, grease behind there) is greased up and that the whole mechanism is greased and adjusted propely.

Re: Clunky Box: Reason and Remedy
 

This is the 3rd C&S Kit on the bike. The first (original) gave up the ghost at 16,000.
The second (Suzuki official and fitted by Suzuki Garage) was knackered at 22,000!
The third and current chain is the most heavy duty chain that DID produce. An X-ring VM2!! The sprokets are made by the Renthal boys. This one should hopefully outlive the bike.

Since new, the gears have always clunked changing down and been as quiet as a mouse on the ups. But at the moment its making the same noise as engaging first from neutral, in every up and down movement.

Re: Clunky Box: Reason and Remedy
 

Check:

Oil level (Bike should be level, use sight glass)
Chain tension (Bike should be level with it's weight supported by wheels)

These are the two major culprits. It sounds like your chains have a pretty harsh life. If you're using the bike daily, as Viney says a scottoiler is going to pay for itself in saving you knackered chain & sprockets.

The SV has 2 points of adjustment for the clutch:
The cable tension at both ends of the cable adjusts the slack (there should be maybe 5mm ish)
The clutch mechanism by the front sprocket is a separate point of adjustment, again as Viney says search for "clutch adjustment" by Sid Squid.

Best of luck :)