Has YOUR gear lever fallen off? - SV650.org

27-05-05, 09:30 AM

So, hearing about Captain Nemo's problems, it seems the number of people whose gear lever has fallen off is growing. I want to get a rough idea of how many people have suffered from the gear lever falling off problem. My bike, Nemos and Mass' are all K4 's' models, but I'd be interested in hearing if others have had the problem. It generally seems to happen fairly early on in the bike's life, so please could you post the approximate mileage that it occured at.

Ultimately, I'd like to present the thread in a letter to Suzuki asking them to look at the problem. Due to the nature of the problem, I doubt they'd do a recall, but even if they just asked dealers to re-torque them at the service/started loctiting them in place, even if only on newer bikes, it'd be worthwhile.

Thanks for your help.

27-05-05, 09:32 AM

I have a young K4, but the lever hasn't fallen off and I'd like to keep it that way. Is there any to check or prevent for it?

Viney · 27-05-05, 09:33 AM

No. Never. Well, only when i have thrown it on the ground!

I would imagine that its more down to maintence than a fault. Just check the 3 bolts. One on the shatf, and the 2 that are on the adjuster bar (Remember that one is a left hand thread!)

BillyC · 27-05-05, 09:35 AM

Nope... I have a K3, and not one of those " oh the seat was too high, oh the pegs are too high" K4 designs

27-05-05, 09:43 AM

Quote:

Originally Posted by Viney

No. Never. Well, only when i have thrown it on the ground!

I would imagine that its more down to maintence than a fault. Just check the 3 bolts. One on the shatf, and the 2 that are on the adjuster bar (Remember that one is a left hand thread!)

As mine and Mass' fell off shortly after dealer services (different dealerships), it would suggest they're not re-torquing it as part of the service, which I would expect them to. Even if the 'fault' is a simple as dealers being lax in servicing, or it not being down in the service schedule, I think suzuki should be made aware.

27-05-05, 09:50 AM

Mine's a K4 on just over 5000 miles and it's not fallen off yet.

I agree with the servicing thing - at my 4000 mile service I noticed after that the radiator was loose... because the bolt at the bottom wasn't there... and the only reason it would have been removed would be to access sparkplugs. Irritating but not as bad as gear lever falling off.

I'll be keeping an eye on the lever now though... have people had them falling off while stationary or while moving... could be interesting if it's the latter

27-05-05, 10:14 AM

my bikes done 4700 miles, it fell off on wednesday,

i serviced it at 4k, and even though i did the service myself, i ticked off the chasis bolts as i checked them, i dont remember the gear shift pivot being on the "bolts to check" list, although i did look at it and it didnt appear lose, to torque it up you would have to remove the circlip and lever, torque and then reinstall. cos it wasnt on the list i didnt think to do it, so in the last 700 or so miles its woked its way out the full length of the thread (about 10-12mm)

i mentioned the gear shift prob at my dealers yesterday, Padgetts in Batley, they said that they werent aware of any other SV's that had had this problem, and that it cant be a major thing or Suzuki would have been in touch.

could have been a problem if it had come off when i was riding though....

27-05-05, 10:20 AM

Quote:

Originally Posted by SVeeedy Gonzales

I'll be keeping an eye on the lever now though... have people had them falling off while stationary or while moving... could be interesting if it's the latter

Mine and mass' were whilst we were moving at speed. It's unnerving as hell to feel for the gear lever and it not to be there.

27-05-05, 10:23 AM

Errrrmmmm NOPE.....thats not normal

27-05-05, 10:28 AM

So, um, what exactly is the plan of action when your gear lever falls off whislt travelling at high speeds/filtering?

Just slip the clutch where necessary and get as far as possible, or stop ASAP and get help? I'm thinking so long as it's one of the lower gears it would still be easyish to get home on. What did everyone else do?

View Poll Results: Has YOUR gear lever fallen off?
Yes, on a K4, 's' bike.	13	25.00%
Yes, on another bike (please specify)	5	9.62%
No, not yet.	34	65.38%
Voters: 52. You may not vote on this poll

27-05-05, 09:30 AM	#1
Ceri JC Guest Posts: n/a	Has YOUR gear lever fallen off? So, hearing about Captain Nemo's problems, it seems the number of people whose gear lever has fallen off is growing. I want to get a rough idea of how many people have suffered from the gear lever falling off problem. My bike, Nemos and Mass' are all K4 's' models, but I'd be interested in hearing if others have had the problem. It generally seems to happen fairly early on in the bike's life, so please could you post the approximate mileage that it occured at. Ultimately, I'd like to present the thread in a letter to Suzuki asking them to look at the problem. Due to the nature of the problem, I doubt they'd do a recall, but even if they just asked dealers to re-torque them at the service/started loctiting them in place, even if only on newer bikes, it'd be worthwhile. Thanks for your help.

27-05-05, 09:35 AM	#4
BillyC Moderator Mega Poster Join Date: Nov 2003 Location: The exiles of Kent Posts: 2,184	Nope... I have a K3, and not one of those " oh the seat was too high, oh the pegs are too high" K4 designs __________________ SV650 K3 - Gone. Now a member of the SV650.org Kawasaki brigade!

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27-05-05, 09:32 AM	#2
thor Guest Posts: n/a	I have a young K4, but the lever hasn't fallen off and I'd like to keep it that way. Is there any to check or prevent for it?

27-05-05, 09:33 AM	#3
Viney Member Mega Poster Join Date: Jul 2003 Location: In the shadows to the left Posts: 7,700	No. Never. Well, only when i have thrown it on the ground! I would imagine that its more down to maintence than a fault. Just check the 3 bolts. One on the shatf, and the 2 that are on the adjuster bar (Remember that one is a left hand thread!)

27-05-05, 09:50 AM	#6
SVeeedy Gonzales Guest Posts: n/a	Mine's a K4 on just over 5000 miles and it's not fallen off yet. I agree with the servicing thing - at my 4000 mile service I noticed after that the radiator was loose... because the bolt at the bottom wasn't there... and the only reason it would have been removed would be to access sparkplugs. Irritating but not as bad as gear lever falling off. I'll be keeping an eye on the lever now though... have people had them falling off while stationary or while moving... could be interesting if it's the latter

27-05-05, 10:14 AM	#7
Captain Nemo Guest Posts: n/a	my bikes done 4700 miles, it fell off on wednesday, i serviced it at 4k, and even though i did the service myself, i ticked off the chasis bolts as i checked them, i dont remember the gear shift pivot being on the "bolts to check" list, although i did look at it and it didnt appear lose, to torque it up you would have to remove the circlip and lever, torque and then reinstall. cos it wasnt on the list i didnt think to do it, so in the last 700 or so miles its woked its way out the full length of the thread (about 10-12mm) i mentioned the gear shift prob at my dealers yesterday, Padgetts in Batley, they said that they werent aware of any other SV's that had had this problem, and that it cant be a major thing or Suzuki would have been in touch. could have been a problem if it had come off when i was riding though....

27-05-05, 10:23 AM	#9
mysteryjimbo Guest Posts: n/a	Errrrmmmm NOPE.....thats not normal

27-05-05, 10:28 AM	#10
SVeeedy Gonzales Guest Posts: n/a	So, um, what exactly is the plan of action when your gear lever falls off whislt travelling at high speeds/filtering? Just slip the clutch where necessary and get as far as possible, or stop ASAP and get help? I'm thinking so long as it's one of the lower gears it would still be easyish to get home on. What did everyone else do?