SuzukiSavage.com - Can't downshift when warm

kojones

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Can't downshift when warm
05/31/17 at 13:15:14

I have a strange problem, gears work fine when engine is cold, but after a while I can't downshift from second gear and quite soon the third gear is the lowest available. It's a PITA in city, but manageable.

I drained the oil today and checked the gear change mechanism under the small cover behind the front pulley, all parts were there as they're supposed to. Replaced the oil with lower viscosity, no help.

Any similar experiences or suggestions what could be causing this?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Can't downshift when warm Reply #1 - 05/31/17 at 13:30:14 The shift arm needs to be pointed straight down. Check if the lever needs lubrication. And yes, it can shift wonkie when it's time for an oil change.
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Can't downshift when warm Reply #2 - 05/31/17 at 13:48:31 You might want to make sure the rod between the pedal and the shift arm isn't flexing or bent, as that would allow shifting up ,but hinder down shifts.
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stewmills

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Re: Can't downshift when warm
Reply #3 - 05/31/17 at 14:00:17

To clarify your issue, does the shift lever go down smoothly and turn the spindle as it should and the gears just don't change internally, or is the shift lever just hard to move down with your foot with gentle pressure.

If the lever moves smoothly, then it it likely not an external issue. If the lever won't move easily, it is likely an external linkage issue such as a bent linkage or just dirty linkage that needs to be greased, etc. at the little ball joints that are (should be) covered by the little rubber covers on each end.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Can't downshift when warm Reply #4 - 05/31/17 at 14:36:39 A flexing shift rod can do that. If you've had to Stomp it into first, it's probably bowed. Oil choices are out there, but the common Go To oil that the old guard uses is Rotella .
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kojones

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Re: Can't downshift when warm
Reply #5 - 06/01/17 at 07:00:54

verslagen1 wrote on 05/31/17 at 13:30:14:

The shift arm needs to be pointed straight down.
Check if the lever needs lubrication.
And yes, it can shift wonkie when it's time for an oil change.

Ok, the shift arm was pointing southwest, hope that repositioning it fixed the issue. There's quite a bit axial play in the shaft, I'll get rid of that with an extra washer if the issue reappears.

The shift lever feels firm when the issue occurs, not allowing any movement down.

Thank you all for your input!

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stewmills

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Re: Can't downshift when warm
Reply #6 - 06/01/17 at 07:11:08

Not sure what you mean about axial play (in the main shift lever, or on the shift rod coming from the engine case?), but make sure you aren't putting something in a bind that is intended to have a little freedom of movement.

Considering that the end of the adjusting rod has ball joint ends, that is going to twist a little but that is ok so long as the rod isn't bent. You just need to grease those ball joints real good (people often ignore and overlook those), and that coupled with your repositioning of the shift arm, you may be in business.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Can't downshift when warm Reply #7 - 06/01/17 at 07:39:07 There was an issue with the 4spds of something happening with the shift mechanism. Doesn't seem to happen anymore.
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kojones Full Member Offline SuzukiSavage.com Rocks! Posts: 223 Finland	Re: Can't downshift when warm Reply #8 - 06/01/17 at 10:51:15 The play is in the shift rod coming from the engine. There's a 1mm thick washer from the factory, measured 1.2mm of play with that. Kicking the shift rod in when stuck gets the transmission working every time, so replacing that 1mm washer with a 1.9mm thick washer.
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kojones Full Member Offline SuzukiSavage.com Rocks! Posts: 223 Finland	Re: Can't downshift when warm Reply #9 - 06/01/17 at 12:47:08 verslagen1 wrote on 06/01/17 at 07:39:07: There was an issue with the 4spds of something happening with the shift mechanism. Doesn't seem to happen anymore. Wonder if mine is a 4 speed, I'm not sure if I've found the 5th gear or not I've spent year and a half repairing the bike, been driving it now for three days.
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Can't downshift when warm Reply #10 - 06/02/17 at 09:08:31 You should be able to see the shift pattern stamped into the side case ,1N234 or 1N2345 We can't tell for sure, you'll need to look as 88 to 94 models were not sold in the U.S. The 5 speed appeared with the reintroduction here in 95 .
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kojones

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Re: Can't downshift when warm
Reply #11 - 06/02/17 at 11:27:34

batman wrote on 06/02/17 at 09:08:31:

You should be able to see the shift pattern stamped into the side case ,1N234 or 1N2345 We can't tell for sure, you'll need to look as 88 to 94 models were not sold in the U.S.

I found the 5th today Cheesy

Mine is a 2001, but wouldn't surprise me if the motor has been replaced.
I greased the ball joints, works slightly better but still no sugar. Jerking the foot lever seems to help, so my shift rod might be twisted. Tried to take it off to check, maybe some another day I have more luck and motivation.

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Can't downshift when warm Reply #12 - 06/02/17 at 13:13:39 the rod has left hand and right hand threads on the ends , loosen the locking nuts and spin the rod ,one way shortens ,the other way to lengthens and removes. rolling it on a flat surface with a light behind it,should show you any bending or warping. Does you clutch disengage fully?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Can't downshift when warm Reply #13 - 06/02/17 at 18:39:54 Have you had to Stomp on it to get it in first? Or did I miss your answer?
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kojones Full Member Offline SuzukiSavage.com Rocks! Posts: 223 Finland	Re: Can't downshift when warm Reply #14 - 06/04/17 at 12:56:51 justin_o_guy2 wrote on 06/02/17 at 18:39:54: Have you had to Stomp on it to get it in first? Or did I miss your answer? First goes in fine. Noticed today that I have to lift the foot lever a bit and then push it down, then the gears engage smoothly and without any problems.
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