'06 SV650 incredibly hard to shift

[OreoGaborio]

So since day 1 the transmission on the race bike has been very hard to shift. Changing the oil helped a little, but it still gave me one helluva sore on my toe, enough that I had to double bandage and tape my toe... AND put a piece of card board inside my boot in order to shift w/o being in pain


It's a LITTLE tough to shift just putting around the paddocks, but it's no where as difficult as it is when I'm at speed.


Any thoughts? Hope it's something simple. Gotta get my hands on a service manual.

[NobodySpecific]

I've got the SV manuals in PDF format. I'm not sure if most e-mail accounts can handle them (kinda big) but if you want I can try and send them to you. They are also available on The Pirate Bay for download (you just need a torrent app) The Pirate Bay - The world's largest BitTorrent tracker It's not illegal, they just didn't have the server capabilities to handle all of the downloads. I'm not sure how well it is seeded, which is why I offered to e-mail them.

Also, have you adjusted the clutch as described here:
FAQ: How do I adust my clutch? AndyAuger's Clutch Mantra - SVRider Board

[RupturedDust]

That's definitely not right. When you squeeze the clutch, do you feel the engine disengage? If nont, it's probably your clutch needs adjustment. If so, then it's a problem IN the transmission, most likely. My first step would be to look and see if the shift shaft that goes into the transmission is bent. Any idea if the bike has been down on that side?

[The Snowman]

Well, you got the bike from Hobbs, what do they have to say about it? Was it that bad when they were using it?

[schleppy]

Hard shifting on an SV is usually indicative of a clutch lever that needs to be adjusted. It's a pretty simple procedure, and has been outlined on svrider.com many times.

P.S. You've got PM.

[nt650hawk]

Sounds similar to a bent shift shaft in the engine on a Hawk.

[Crash Dummy Denno]

Hard shifting on an SV is usually indicative of a clutch lever that needs to be adjusted. It's a pretty simple procedure, and has been outlined on svrider.com many times.

P.S. You've got PM.

he's racing so he only uses the clutch lever when he's downshifting

[Qfactor]

I would check the parts diagrams and pdf fiches for the shifter rod assys (the ones that go into the cases.

I would be willing to bet there's a bearing (or bushing) that's getting old or really dry...

Oreo - Have you tried spraying some lube on where the shifter rod goes into the cases?

try it and see if it gets little better...

Q

[TLRMan]

With the engine off, and spinning the rear wheel, does it shift up/down OK?
If it does, clutch pack sticking, or bent clutch rod, or rod out of adjustment. (adjustment at rod side not handle side). I'm sure they have an adjustment...

[Doc]

I am gonna go with Gino.

[BMFR6]

FactoryPro Shift Kits, detent arm

helped mine

[OreoGaborio]

Clutch lever & cable is adjusted just fine.

Schleppy, thanks in advance for the manual

Mark, you gonna be around at all this weekend? Gonna try & tear into it.

[TLRMan]

Clutch lever & cable is adjusted just fine.

Schleppy, thanks in advance for the manual

Mark, you gonna be around at all this weekend? Gonna try & tear into it.

Pete, Airshow at Westover on Saturday...
Sunday should be clear....I'm gonna be at Degsy's on Friday afternoon, and have to fit TJ in too.

[Sheppo]

2006 Suzuki Motorcycle Parts for SV650, Control & Brake - GEAR SHIFTING (MODEL K5/K6)


here is the link to what's inside...

[TLRMan]

it's part #18 and #19 that sets up the adjustment first, then you set the cable slack at the clutch lever. Many miss this!

[TLRMan]

Pete, still got some moving cleaning up to do, but I bet I could hit you after work on Thursday...if it's just the rod adjustment, you are out of it in 15-20 minutes...

[NobodySpecific]

it's part #18 and #19 that sets up the adjustment first, then you set the cable slack at the clutch lever. Many miss this!

The link I provided addresses this and gives a procedure for doing this on the SV

[TLRMan]

The link I provided addresses this and gives a procedure for doing this on the SV

Sorry, didn't read the link, because this is the 1st thing you look for.
If the arm doesn't rotate enough, and the rod is too far back, it won't engage the clutch enough to release the plates, and will still put tension on the drive dogs. If the clutch plates and steels are warped, or the screws that hold the pack together are bent will also cause an issue at high rpm's.
I do this in my sleep...

[RandyO]

adjust shift linkage so that the linkage rod is perpendicular to the shift arm (you may have to reorient the shift arm on the splines ) for best leverage, make sure linkage is tight, clean & lubed, not sloppy, it it is, replace it

[akira700]

FactoryPro Shift Kits, detent arm

helped mine

EVO Shift STAR Kit benefits?
Easier upshifts under hard use.
Effortless downshifting
Driving in flip-flops? The STAR is a "must have!

Pete, this is for you then!