SuzukiSavage.com - shifting linkage broke

s40guy

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shifting linkage broke
07/21/14 at 16:42:27

Went to ride yesterday. Started my bike up push down to go into first gear and crack. Linkage broke. For some reason my linkage on my 2006 S40 had a slight bend in it when I bought it used. I had it for little less than a year and she gave out. The new ones I looked at on the 2012 and 2014 S40's seem to have a straight shaft linkage. Nothing seemed like it was hard to shift, like no tranny damage or anything. Just seemed like the linkage gave out near the bend in the rod. The linkage broke right at the bend so I assume that that is all it is. Anyone have any suggestions as to what else to look for or do you think it was just weak linkage? never had any trouble shifting or anything else the whole time I owned the bike. Anyone else ever have this problem? Anyone else have a straight linkage or one with a slight bend? I ordered my new one yesterday on line and I should have it by mid week. Thanks, S40 Guy. Undecided

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Demin Serious Thumper Offline We need more chlorine in the gene pool Posts: 2435 Warren,Ohio Gender:	Re: shifting linkage broke Reply #1 - 07/21/14 at 18:08:36 Some people think you have to stomp on the peg to shift.I see it a lot when I teach the MSF class.
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engineer Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 872 Gender:	Re: shifting linkage broke Reply #2 - 07/21/14 at 18:11:43 It is probably just a case of the PO abusing the linkage by stomping on the lever and bending the somewhat fragile rod. The bend set up a strained area that finally gave way. A replacement will fix it.
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s40guy YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 33	Re: shifting linkage broke Reply #3 - 07/21/14 at 18:17:55 That is kind of what I thought. I always shift very careful and never try to slam it into gear. Can you tell me if the linkage on your bikes are straight or have a slight curve? the new ones I saw on S40's looked straight to me. Thanks, S40Guy
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Steve H Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1223 Spartanburg, SC Gender:	Re: shifting linkage broke Reply #4 - 07/21/14 at 18:21:25 It should be straight.
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WD Serious Thumper 2005 No Login Offline Professional "scooter trash". Posts: 5207 Rosemark TN Gender:	Re: shifting linkage broke Reply #5 - 07/21/14 at 20:41:45 Straight, very cheap grade of metal, order and carry a spare. Even babying them, they can snap w/o warning.
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s40guy YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 33	Re: shifting linkage broke Reply #6 - 07/22/14 at 16:56:31 Thank you guys. Once I get the new one on and I order other parts again I will get an extra one to have on hand. S40Guy
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s40guy

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Re: shifting linkage broke
Reply #7 - 07/24/14 at 18:41:32

Just installed the new linkage and huts. Very easy to do. I threaded the rod and nut into the front shifter end and left about 3 threads showing. The removed the shifter connector from the shaft and threaded on the rod and nut til about 2 threads showed. (I marked the spot where the two ends came off to get the shifter right). Out it on, tweaked the height a bit and test drove. The new shaft seemed much thicker than the original one and it was straight. Also I changed out the rubber foot pad on the shifter. the new one is a little smaller diameter on the outside than the original one. Works great and shifts real nice.

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BobH

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2008 Stock S40; 2015
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Re: shifting linkage broke
Reply #8 - 07/24/14 at 19:35:41

s40guy wrote on 07/24/14 at 18:41:32:

Just installed the new linkage and huts. Very easy to do. I threaded the rod and nut into the front shifter end and left about 3 threads showing. The removed the shifter connector from the shaft and threaded on the rod and nut til about 2 threads showed. (I marked the spot where the two ends came off to get the shifter right). Out it on, tweaked the height a bit and test drove. The new shaft seemed much thicker than the original one and it was straight. Also I changed out the rubber foot pad on the shifter. the new one is a little smaller diameter on the outside than the original one. Works great and shifts real nice.

Glad you are back up & running. The threads on the rod work like a turnbuckle. One end is a reverse thread, which means you can start both threads at the same time and turn until you have the adjustment you want. No need to remove the "shifter connector" to thread that end.

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Bob

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