Hey guys! This bikes a 86 with the 4 speed trans. It was a total basket case when I bought it, the engine was in the frame but the stator cover and a bunch of other parts were in a box when I got it. It took me almost 3 years off and on and a ton of repairs before I finally got it running. I did take the clutch cover, shifter cover and mechanism, and as I said the stator cover was already off. I did it to clean it up and reseal as much as I could before I put it back together. Now it runs pretty good and rides fairly well except it won't go into first gear, feels like when trying to downshift that it's at the end of the shift pattern even though it only goes to neutral. When up shifting from neutral it grinds a bit before it'll go into second gear. Shifting to third gear is fine and shifting to fourth gear sometimes will go right in and sometimes it doesn't want to go at all. I was running Mobil 1 v twin oil but will be switching to 15w 40 Rotella t5.
I pulled the shifter mechanism back off to see if maybe I didn't get it lined up right when I put it together but didn't see anything obvious.
Any thoughts on what I should look for? Unfortunately it didn't run when I got it so I have no idea if this is self inflicted or was a preexisting problem.
Oh, I also installed a 4inch forward control set up but don't think that's the problem but I could be wrong.
Sorry for the long post but wanted to give as much info as I could. Thanks in advance!

Congratulations , you've been further into the engine than most.
If it's self inflicted , you're not going to be laughed at.

Ok, hope to get back to work on it this weekend as I'm waiting on a new stator, yah, that went bad too.
Thinking about upgrading to a 5 speed if I have to replace the bottom end. Are any of the years not compatability to my 86? What else might I need to change?
Thanks.

If you change to a 5 spd, you'll need to keep the 4 spd rotor as it's timed to the cdi.

Thanks Don definately considering it. Might a winter project though. Wanna get some riding in before summers over. Seems they keep getting shorter up here in Northeast Ohio!  

suzuki motorcycle sequential shift mechanism


Not to be a snot, though I Am imminently qualified whether I have a sinus problem or not, I ran that through a search engine and saw stuff I would study if I was in the same trouble you're in. You've done pretty dang good, hope you win it.

You don't know why it was torn down, do you?
You Might be chasing the problem that the seller had.

mastercarstech wrote on 06/24/16 at 09:54:38:

The 4 spds have a problem with the starter because of the 1way clutch they use.
On shutdown, if the piston comes up on the compression stroke, it will reverse the engine and engage the starter with enough force to break teeth or bust out the bosses for the starter gears.

It could be when PO was reassembling the side cover he placed the washer on the wrong starter gear ,then tried to force on the cover causing it to crack,it"s been done before as the washer will fit on either gear,but jams them and could account for some of your wires doing a meltdown.