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Message started by wearsabrowncoat on 06/06/13 at 17:04:27

Title: Shifting too hard?
Post by wearsabrowncoat on 06/06/13 at 17:04:27

Down shifting at a stop sign on the way to work today when I could no longer feel the shifter. Looked down and saw it hanging near the ground. Reached down and pulled it up and the lever locked in the up poistion. Luckily I was in second gear and was able to limp home. When I got home I discovered the linkage from the shifter to the transmission was snapped in half.

About a week ago I ordered a forward control extension kit. That should come with a new longer link, right?

Pictures when I get back home.

Title: Re: Shifting too hard?
Post by Serowbot on 06/06/13 at 17:44:06

17050112130102120F170E030F0114600 wrote:

That should come with a new longer link, right?

Yup...
...be gentle you brute.... ;D...

Title: Re: Shifting too hard?
Post by justin_o_guy2 on 06/06/13 at 21:12:30

Ive never had to cram a shifter in place on anything. If youre sitting in neutral with your clutch pulled in for long, the gears will stop spinning & gettin in 1st can be hard. Any time youre having a problem getting in gear, let the clutch out a little to make it spin up inside, then gently Pres down,, If youre lifting that foot off the peg to hit the shifter, youre doin it way wrong,

Title: Re: Shifting too hard?
Post by Serowbot on 06/06/13 at 22:55:47

Yup,... what JOG said..
Bike trannie's ain't like cars... they aren't built to shift in stasis...
...if you feel any resistance,... pulling the clutch will re-jog the gears, and allow them to mesh...

:-????...
(Did anybody get that I said.... re-JOG?)... :-?... (as I support JOG's advice? but, referring to gears?)... ...Score!... It's like brilliant, but slower...
Arh arh arh!.... ;D...

A tiny win... ...but a win...
Such opportunities are irresistible....:-?...
Eloquent response JOG... I just couldn't resist the reinforcement...

Title: Re: Shifting too hard?
Post by wearsabrowncoat on 06/06/13 at 23:56:19

Pictures

Title: Re: Shifting too hard?
Post by wearsabrowncoat on 06/06/13 at 23:58:28

Pic 2

Title: Re: Shifting too hard?
Post by wearsabrowncoat on 06/07/13 at 00:02:02

As luck would have it, my 6" FC set was waiting when I got home. However, Looking the parts over it seems the shift link part is also an extension so I need an operable original part. I'm going to post up in the market section for a replacement. What is the official name of the busted part pictured above?

Title: Re: Shifting too hard?
Post by justin_o_guy2 on 06/07/13 at 01:37:00

WEll,, its officially junk, now,

what? Thats not what ya meant?

Title: Re: Shifting too hard?
Post by oldNslow on 06/07/13 at 07:09:09

405256454456554558405954585643370 wrote:

http://www.bikebandit.com/2006-suzuki-boulevard-s40-ls650/o/m147605#sch512178

It's #38 in the picture. Rod,gear shift.

Title: Re: Shifting too hard?
Post by apache snow on 06/07/13 at 07:31:30

Or even cheaper here.

http://www.boulevardsuzuki.com/fiche_section_detail.asp?section=1442289&category=Motorcycles&make=SUZUKI&year=2011&fveh=39862

Title: Re: Shifting too hard?
Post by arteacher on 06/07/13 at 09:12:00

Don't forget to grease the pedal while you have it apart.

Title: Re: Shifting too hard?
Post by wearsabrowncoat on 06/20/13 at 16:27:40

Not sure if l will get the response I need without starting a new thread but here is an update and my current situation.

Got the shift rot replaced today. Not too difficult after I figured out the reverse thread thing. However perhaps I didn't put it back together right because I can't get it out of second. A short recap may be in order: I busted the shift rod downshifting into neutral. Once I realized what happened I reached down and pulled up on the lever. Somehow this got me in second and I limped home. Now that the rod is replaced I can't get it out of second. Now that I think about it I'm not sure how pulling up on the lever got it in second if the rod was busted but maybe it was still hanging on by a thread and that was the last straw.

Title: Re: Shifting too hard?
Post by oldNslow on 06/20/13 at 17:21:31

I think the first thing I'd do is figure out a way to get the bike propped up with the back wheel off the ground, disconnect the linkage, start up the bike and see if I could shift it using just the little lever on the shaft. Maybe use a pair of vice-grips or something for a handle. At least find neutral.

Get someone to work the clutch while you shift it up and down through the gears with the linkage off. If it shifts like that you probably just need to recheck how you hooked the rod and new forward control stuff up. If it won't shift doing it like this then something happened in your transmission. I don't think that's very likely actually but it's possible.

Title: Re: Shifting too hard?
Post by wearsabrowncoat on 06/20/13 at 18:04:24

I actually was in the process of building one of the wooden bike stands to swap the rear shocks. I'll have to finish it up and prop up the rear end. I have all ready tried rolling it back and forth as well as riding it down the street in second while working the clutch and trying to get the shifter to budge - although nice and easy this time. I don't need another week down time waiting for another shifter rod.

Title: Re: Shifting too hard?
Post by oldNslow on 06/20/13 at 18:41:04

Quote:

I have all ready tried rolling it back and forth as well as riding it down the street in second while working the clutch and trying to get the shifter to budge

Do you have a Clymers manual? Take a look at the section in chapter 6 about the external gearshift mechinism. It's inside the cover just behind the alternator cover. If you absolutely can't get the bike to shift (even by hand with the wheel off the ground) I've got a hunch the problem might be in there. I'm not going to be any help with specifc advice though. I've never been in there on a Savage. Hopefully someone with more insight will jump in.

Title: Re: Shifting too hard?
Post by WD on 06/21/13 at 10:08:06

You do have the little internally splined piece facing straight down, right? If not, you may just not have enough "throw" on that piece to make the shifter "guts" move. Double check it, make sure the finger part is straight down, let us know what happens.

Title: Re: Shifting too hard?
Post by wearsabrowncoat on 06/22/13 at 15:35:10

I took the shifter rod assembly back off and adjusted the angle of how it connected to the knurled rod coming out of the transmission. That must have done the trick because I am back in business. Future note to anyone doing this is to put a witness mark on that portion of the assembly before taking it off to eliminate the guess work.

Title: Re: Shifting too hard?
Post by wearsabrowncoat on 06/22/13 at 15:39:00

I posted before I read the last comment. Yes the internally splined part is what I adjusted. Wouldn't say it is straight down but much closer to down than horizontal now. What is the correct procedure to align it, should the transmission be in neutral?

Title: Re: Shifting too hard?
Post by Routy on 06/22/13 at 19:09:42

I remember a few yrs ago when I installed the FC kit, I had to move the arm on the transmission by 1 spline, to get it to completely shift.
W/o looking, I would assume the arm should be straight down when in neutral.
But when I think about it, seems like it should be straight down in any gear.

Title: Re: Shifting too hard?
Post by WD on 06/22/13 at 20:52:06

Correct procedure? Start with it close to straight down, adjust the angle until it will smoothly drop into each gear. Each bike is just a touch different than the ones that left the line directly before and after it.