I've had my S40 for about 2 weeks now, and I'm wishing this thing had more gears.  So I'm wondering if there is a drop in transmission or some kind of way to get more gears that will give me a smooth second gear in slow turns and lower RPMs when cruising on the highway at 75mph.  Any ideas?

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Haven't heard of any.  Adding more gears is a major undertaking even for the manufacturer.

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I understand your complaint about an awkward point when turning corners in second or first.  Today I rode my other bike around some well know corners and noticed it had exactly the same problem on those same corners as the Savage does, too fast in second so had to do them in 1st.  That's the way it is.  I had a dirt bike that did all the corners in second but it wasn't any good on the open road.

You shouldn't be lugging the engine in second.  If you are going that slow downshift to 1st.  That goes for any vehicle.

Many people on this forum agree that 5th gear should have been made with a bigger gap from 4th to 5th so that highway speeds could be done at lower revs.

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Some people change the final drive ratio.  There are two ways to do it.  One is by replacing the belt drive with a chain and sprockets.  Then you can pick whatever ratio you want.  Some on this forum have substituted a different final drive pulley for the existing belt drive.  Both methods require a decent amount of work and expense.  I have a slightly larger tire on mine which changed my ratio slightly, I can feel it when I start out in first gear.  There are some good threads on this forum about changing to a chain and sprocket.  Changing the overall ratio will help your top end revs but it will make your 2nd gear turns even more difficult.  Easiest solution, downshift to 1st when negotiating a tight street corner.
 

I'm bummed there is no drop in transmission for the S40.  That Versy guy should just make a drop in 6 or 7 gear transmission.  I'm pretty sure that would sell like hotcakes.

I'll be honest, there is no way I am doing a chain conversion on this thing myself.  Is there is a pro in the DFW area that will do it for me?  If so, I have the money.  Other than that, I'm more likely to buy one that has already been converted.  Anyone selling one of those?

verslagen1 wrote on 05/13/14 at 19:04:01:


What if I bought a new one of your choice and sent it to you?

http://shop.rycamotors.com/chain_conversion_kit.html

Their is instructions on the web site.  If you got tools, the forum can answer whatever questions may come up.

Ride it for a few months,, YOull get used to droppin into first & ramming the thing thru turns

Vibration? That's easy... change the handlebar for something comfortable and order some decent grips. Decent means like the old Gran Turismo jobbies that Emgo (among others) is cranking out copies of. Finding them in 1" can be a bit of a pain, but worth the effort. Also, pop off one riser cap, drill a hole, and fill the bar with sand or bird shot. No more vibration.

Gearing? Pull off the front pulley cover (3 8mm bolts). Spin off the 32mm nut. Swap on the front chain conversion sprocket. Put the nut and the cover back on once the chain is draped around the sprocket. Drop out the rear wheel assembly (2 bolts you back off, and 1 axle bolt you pull out). Remove the pulley bolts, toss the pulley in the junk bin, bolt on the sprocket. Install the wheel all the way forward in the swingarm notches, drape the chain around the rear pulley, add the master link (clip type is fine). Set your tension. Adjust the rear brake. Go for a ride. Reset the rear brake a couple more times.

Takes about as long to do as to type. Have not done either of my current rides, have converted another local one. Piece of cake.

I'm lazy, I just keep the engine wound up a bit.