SuzukiSavage.com - Lost 3rd 4th and 5th Gear.

23Skidoo

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Lost 3rd 4th and 5th Gear.
03/28/13 at 01:48:05

Hi, I lost 3rd gear upwards on the way to work this morning.. Sounds a bit weird but when in 1st the lever feels almost if it's dropped a little (although that could be a bit sub concious) and I have some play between 1st and neutral 2nd is a bit tough then it won't go any higher..

Sorry for a bit of an open ended question, I'll have to get my local mechanic to look at it but a heads up might be handy...

Many Thanks

AJ

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18101 Camp Springs, Kentucky Gender:	Re: Lost 3rd 4th and 5th Gear. Reply #1 - 03/28/13 at 02:47:26 The first thing I would check is the lubrication and movement of the external shifter and linkage.
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Cavi Mike Serious Thumper Offline Thumper n00b Posts: 1005 Rochester, NY Gender:	Re: Lost 3rd 4th and 5th Gear. Reply #2 - 03/28/13 at 03:44:27 Can't diagnose or fix something like that without taking the engine apart.
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23Skidoo

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Re: Lost 3rd 4th and 5th Gear.
Reply #3 - 03/28/13 at 04:07:33

Dave wrote on 03/28/13 at 02:47:26:

The first thing I would check is the lubrication and movement of the external shifter and linkage.

Will do, that did dawn on me as well...

Quote:

Can't diagnose or fix something like that without taking the engine apart.

I know mate, to many factors... I'll have a better look after work if I can limp home in 2nd....

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WD Serious Thumper 2005 No Login Offline Professional "scooter trash". Posts: 5207 Rosemark TN Gender:	Re: Lost 3rd 4th and 5th Gear. Reply #4 - 03/28/13 at 07:17:47 I'd lay even money that your shift linkage bent. Really common failure on Savages, the factory part is barely worthy of being classed as pot metal. If that is all that happened, you can unscrew the rod, straighten it, and when you go to reassemble the unit, sleeve it with a piece of thick wall tubing.
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verslagen1

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Re: Lost 3rd 4th and 5th Gear.
Reply #5 - 03/28/13 at 08:30:22

Cavi Mike wrote on 03/28/13 at 03:44:27:

Can't diagnose or fix something like that without taking the engine apart.

Mr stealership intern?

Get down on your hands and knees and eyeball the thing.
The rod and threads should be straight.
And knicks or bends and the rod will break sooner or later.
The the operator on the shaft should be pointing straight down... more or less.
Now operate the thing
hitches in the getalong will affect shifting.
Does it stick or bind? adjust lube or bend

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Boofer

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Re: Lost 3rd 4th and 5th Gear.
Reply #6 - 03/28/13 at 11:04:49

I would get someone to sit on the bike and slowly rock it back and forth while I shift with my hand. This can help you feel the notches or lack of notches. It also lets you visually check to see if the shift lever is rotating on the splines without working the shift fork inside. Plus listening can give you a clue as well. Good luck.

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Trippah Serious Thumper Offline I ride, therefore I am. Posts: 2517 central Mass Gender:	Re: Lost 3rd 4th and 5th Gear. Reply #7 - 03/28/13 at 11:15:08 and if you get to only one gear, you will have single single ...hope it's just the linkage.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Lost 3rd 4th and 5th Gear. Reply #8 - 03/28/13 at 13:33:42 Sounds a bit weird but when in 1st the lever feels almost if it's dropped a little. Which is exactly how it would feel if the shifter rod looks like a rainbow., WD nailed it, problem and solution
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rfw2003 Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1108 Yantis, TX	Re: Lost 3rd 4th and 5th Gear. Reply #9 - 03/28/13 at 14:18:08 I had the same problem shortly after I put my fwd controls on. Now why did I have the issue you ask? I forgot to lube the shifter mount point and also because of this the shifter was harder to push and I bent my shifter rod. So the solution was straightening the rod and lubing the post that the shifter is mounted on. R.F.
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newb_Jack Ex Member	Re: Lost 3rd 4th and 5th Gear. Reply #10 - 04/03/13 at 08:44:21 I just had this happen to me as well. Bent the shift rod. I can see that it has "rainbowed". Do I need to put the bike on a jack to undo the rod, in order to bend it straight? Or can I just unscrew the rod with a wrench while the bike is on its side stand?
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Re: Lost 3rd 4th and 5th Gear.
Reply #11 - 04/03/13 at 09:06:33

jackedmusic wrote on 04/03/13 at 08:44:21:

I just had this happen to me as well. Bent the shift rod. I can see that it has "rainbowed".

Do I need to put the bike on a jack to undo the rod, in order to bend it straight? Or can I just unscrew the rod with a wrench while the bike is on its side stand?

You can do it with the bike on the side stand. Be aware that one end of the rod has right hand threads, the other end left hand. Take the shift lever off the splined shaft that comes out of engine case, loosen the locknuts at each end of the rod and unscrew it.

After you get it straight, and back on. you can spin the rod in one direction or the other to adjust the hieght of the shifter to your liking before you tighten the locknuts.

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rfw2003

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Re: Lost 3rd 4th and 5th Gear.
Reply #12 - 04/03/13 at 09:23:55

Soon I will be making beefier sifter rods out of SS 1/4" round for those of you that want the shiny rods and mild steel for those of you that want to paint your rods to match the color of your bikes. I will update in the market place when I have them available. I will have them in stock length and also will make them to what ever length you need.

R.F.

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newb_Jack

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Re: Lost 3rd 4th and 5th Gear.
Reply #13 - 04/03/13 at 09:32:59

oldNslow wrote on 04/03/13 at 09:06:33:

You can do it with the bike on the side stand. Be aware that one end of the rod has right hand threads, the other end left hand. Take the shift lever off the splined shaft that comes out of engine case, loosen the locknuts at each end of the rod and unscrew it.

After you get it straight, and back on. you can spin the rod in one direction or the other to adjust the hieght of the shifter to your liking before you tighten the locknuts.

Excellent. Thank you!

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srinath

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Re: Lost 3rd 4th and 5th Gear.
Reply #14 - 04/03/13 at 17:07:07

Yea I've received a savage with a bent shift linkage ... wont get out of 2nd the guy said. Yea it wont, cos it was hitting the foot peg 1/2 way in its travel if I recall.

You may have to make the right part ... use a thicker rod not the dinky original size and cut the right dia and pitch threads in it ... then paint it or otherwise make sure it doesn't corrorde @ the threads so you can adjust it without getting the threads weaker ...

Cool.
Srinath.

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