Hi everyone,
I’m having some trouble with my 2016 Suzuki Savage and could really use some advice.
When I first got the bike, I changed the handlebars and used a different clutch cable. Unfortunately, that cable turned out to be too long, so I switched back to the original handlebars and clutch cable, replaced clutch rod with a longer one. Now, I can engage and disengage the clutch by hand, but when I start the bike and try to shift gears, it seems like the gears are skipping.

Here’s what’s happening:
-I start the bike in first gear.
-When I try to shift up, it feels like the gear lever goes all the way up and skips the gears.
-Finding neutral is very difficult; even the smallest movement with my foot changes the gears.
-When I shift from 1st to 2nd, it seems to go into 2nd, but I can’t shift any higher. It feels like something is preventing it from going into 3rd and 4th.

I haven’t taken off the left side cover yet to inspect it, but I’m wondering if the issue could be related to the foot pedal adjustment. Could it be that the clutch isn’t getting enough pressure, or maybe too much, to change the gears properly?

A lot of parts on the bike are aftermarket and custom, but the engine is still the same. I’m not sure what to do next. Should I:
-Open up the left side case to see what’s going on inside?
-Adjust the foot linkage (I think I tried this already)?

Any help or suggestions would be greatly appreciated. Thanks in advance!

Arty Dodger wrote on 09/25/24 at 16:27:01:

try starting in neutral, easier to find when off.
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can't be done, gears only shift 1 at a time. You can skip n, but not 2 gears, just not enough teeth on the shift mechanism.
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Probably bad adjustment of the shift lever
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If your lever position is too far 1 way or another, it won't shift right.

the shift lever should point straight down.

next thing I think happened is you put in a longer shift rod, maybe it's too long.
look at the markings on the side of the case and compare with the clutch lever, the clutch lever should be in the middle.

Great input guys!  Good details!

Badwolf - Great explanation on how to make the adjustment!  I did it wrong the first time I adjusted mine until someone pointed out I was making the adjustment in the wrong place.

Why did you put the longer rod in? It sounds like the clutch is not fully disengaging, which causes the issues with shifting you're describing.

Bring out the longer rods!

Thanks for the explanation. Here's a photo of the shifter arm and linkage. With it in neutral, the position is not entirely straight up and down so that might be the issue?

I put a longer rod in it because I tried to put a longer handlebar on it which needed to replace the clutch cable. Then the piece where the clutch cable adjustments that's attached to the engine broke off, so I fixed the issue. But it wouldn't disengage when pressed in. Changing to a longer rod seemed to fix that issue. Then I moved back to my old handlebars,but didn't change back the rod length. Maybe if I change back the rod and adjust the lever, then hopefully that'll fix it.
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verslagen1 wrote on 09/25/24 at 19:24:36:

Here’s a pic of mine with the bike in neutral.  My bike shifts fine.  The rod is slightly higher where it connects up front (slightly lower at the splined shaft).

It looks like we're only maybe 1-2 splines different.  It must be your longer rod.  I have an average normal length rod.

Verslagen - Maybe I’m old and blind, but I don’t see an index mark on the end of the splined shaft.  Somebody schooled me to get the rod level and make any adjustment up front and not at the splined shaft.  But you obviously need to have it right at the splined shaft.  Where is this elusive index mark?