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99-04 SV650 05 Shift Kit Installation

just an update, i used this @ the past AFM races.

works great. not 1 missed shift throughout the entire weekend. also no probs doing clutchless shifts from 1st to 2nd. great mod for not much money.
 
Late last summer I swapped out the engine that came with my '00 trackbike (burning oil) with an '03 engine, and we put the Factory spring in. It turns out that this engine with supposedly only 7000 miles on it likes to drop out of 5th down into 4th at high revs and acceleration. Like at about the starter's tower at Thunderhill for me :( It would be slightly less dangerous if it just dropped into a false neutral, I think.

I think that I've probably got worn shift dogs and that the star won't help me with this, which is extremely dissapointing. Gambled $2000 for a Cycle Salvage motor + labor and lost.
 
change the star.... It will probably help. I had the same problem and my shift forks/ dogs were not that bad. (Just before I broke one)
 
MackeyStingray said:
...
6. bend the lock washer holding the center hub nut use either an impact gun or a clutch holder tool and remove the nut w/ a 27mm socket/wrench
...
Click to expand...

And here's where I'm stuck. Did you use an air wrench? The stick through the wheel isn't working so well with all the flex in the cush drive, and I wonder whether I should be worried about the chain, too. My hand impact driver isn't cuttin' it and I only have a piddly little 1-gallon compressor.
 
Hey Calvin, nice photos and thanks for the info. I'm working on this upgrade now, along with replacing clutch plates and springs. a question: did you replace this piece as well? (indicated with red arrows :twofinger) looks like a bottle opener.

I ordered the other 3 parts that you had listed, but didn't find reference to this pieces P/N#, or you having changed it. (i'll read the thread again)

let me know. i have to call back and add it to the parts order.

thanks in advance.

2699702-2493900-img_0180_2_.jpg
 
didn't replace it to part you pointed to rick.

just the parts that i listed in the 1st post
 
thanks fellas. yeah, i didn't order it, cause it looked different in the micro fiche at the dealer. and didn't see it posted here, but wasn't sure. thanks again. ordered all parts, no the f'ing wait starts. 5 business days....shit! :laughing

edit:
I ordered #15, #14 and #10 in the above microfiche link that davetoo posted.

new plates (total 13) OEM
3 OEM springs.
barnett springs (come in 6 pack)
filed the tangs on the clutch basket (carefully and evenly) and they're smoother than a babies bottom now.
new lock washer
o-rings
paper gasket for entire housing, in case I decide to take it off.....i don't have girlie hands like mackey.... :later
 
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DaveToo said:


I think that part basically stops the shifter arm travel at roughly the right spot and then the detent arm and star set the final position of the shift drum/forks/gears.
Click to expand...
that part actually is what makes shifts.it rotates together with shift lever(the one you kick with foot)and ears on back turn star.star is bolted to drum which moves shift forks.detent wheel makes sure star does not go to far and locks drum in position.each valley on star is one gear.
 
TWF said:
that part actually is what makes shifts.it rotates together with shift lever(the one you kick with foot)and ears on back turn star.star is bolted to drum which moves shift forks.detent wheel makes sure star does not go to far and locks drum in position.each valley on star is one gear.
Click to expand...

reading your explanation of what the shift star does....would there be consequence for replacing it and installing new shift star in wrong rotation. by this I mean, if I put the shift star in place, as was the previous one, but rotated to far to either side....would this cause the bike to not shift properly and/or come out of gear and appear to go into neutral.

I ask, because I just did the entire replacement along with clutch plates, and then I just turned it on, warmed it up and let it idle for a while. then put it into first gear, and slowly moved it around. unfortunately I hadn't had a chance to get it out and see how it was working after putting everything back together. it seemed to pop into gear pretty well, and the clutch actuated well. then I rode at slow speed a bit, in my apt. complex...but a bit down the way it would not actuate...in otherwords it felt like it was going into neutral....not shifting into neutral....but all of a sudden i had no drive on it. so i shifted up, and it would clunk into gear...i didn't want to jam on it or anything...but then I went down to first gear, and it felt like the gears were rattling...or something rattled before engaging together...i didn't ride it anymore, and parked it...but I'm not sure that it's the clutch.

only reason is because the clutch engages well, it doesn't want to move forward even if the clutch lever is pulled in, or let out.

i'm not sure if the shift star was put on right. (i took plenty of photos before dissasembling, followed the photos and manual to replace) I had a feeling that it was on, but turned to far forward, as I recall Zoran saying that this is what actuates the gears...so i'm thinking that it's not actually actuating them properly. have any of you heard of this, or had it happen, or any ideas.?

when I put the clutch plates in, I soaked each one in oil, and made sure they were coated well, then I stacked them all together, covered in oil, till i was ready to install them. and then installed them, and closed everything else. i hadn't moved the bike in about 5 days after reinstall. did i fuck something up by doing that?

do i need to pull the plates and soak them in oil longer?

or just reassemble the shift star and stuff. i put them back in as the manual says and also the way I took out the old ones. I'll have to go thru my pics. when I get home.

anyway, whatever help ya'll can give is appreciated, thanks.
 
you can'tput star wrong,it has 2 pins on back that are offset and fit in holes.there is only one way star can go on.
two things that might be wrong in your case.first is make sure that circleclip is on shift shaft where shaft exits case on left side.if not on properly shaft will move in and out in which case it can hit back of clutch basket or/end slip of off the star.
second thing is arm with detent wheel.there is 4 parts here,spring,washer,arm and bolt.bolt has shoulder.when installing you have to make sure that washer is up and around shoulder of bolt when bolt is tightened.if not arm will not move freely and nothing will stop star from turning to far.
 
TWF said:
you can'tput star wrong,it has 2 pins on back that are offset and fit in holes.there is only one way star can go on.
two things that might be wrong in your case.first is make sure that circleclip is on shift shaft where shaft exits case on left side.if not on properly shaft will move in and out in which case it can hit back of clutch basket or/end slip of off the star.
second thing is arm with detent wheel.there is 4 parts here,spring,washer,arm and bolt.bolt has shoulder.when installing you have to make sure that washer is up and around shoulder of bolt when bolt is tightened.if not arm will not move freely and nothing will stop star from turning to far.
Click to expand...

okay, gonna tear it apart in the next two days, and check these things.....

edit: I think you are talking about the circlip on the left side of the bike on the shift shaft. I'm talking about the circlip on the right side of bike, inside the case that allows me to remove the shift star. either way, i'll replace it too. and check the one on the left side of bike.

the circlip took a bit of a beating when I first took it off. but I didn't replace it. cause I didn't have one at the time. I will get a couple of spares and replace when I go back in there....

thanks Zoran
 
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circlip is on outside of motor.you can see it if you dont have countershaft sprocket cover on.
 
TWF said:
circlip is on outside of motor.you can see it if you dont have countershaft sprocket cover on.
Click to expand...

aha, just figured out what you meant, and edited my post. haha

will check it too. don't have the cover on the bike either. will post some photos tomorrow morning, when I get home from work.
 
and I just figured which one you talking about :)
I never take that one off,I just undo linkage on left side and pull complete shaft out.
 
so i finally got a chance to dive into the bike again, today.

I removed the main cover on the right side. I also removed the snap clip on the left side of the bike, and pulled the shift arm thru...thanks Zoran.

I took some pictures, that might help in seeing if I assembled something wrong.

the only other thing I can think of is that I didn't soak the plates long enough. but who knows. i'm just a shade tree mechanic. :teeth besides, the clutch didn't seem to have a problem engagin/disengaging, just the gears seemed to pop out or go to false neutral.

also, removing the shift arm was way fucking easier than what I did last time.

Here is what I saw, when I removed the clutch basket and all it's components to reveal the shift star and such.......

the area highlighted with the red circle was actually located where the red arrow is pointing to, when I first dissasembled it. I don't know if this is of any particular matter, or if the shift star just goes around in circles with the shifting......my question. should the section (missing the pointy part - circled in red) be located by the little shift arm (Stopper Comp, de) or does it matter where the star is rotated to, when it is assembled.

my thought was that this is why it wasn't shifting properly.

the snap rign on the left side of the bike was fine. albeit it greasy and dirty, which I cleaned.

2737593-img_5090_2_.jpg
 
next thing I noticed, and after viewing Mackey's photo at the beginning.....

question:

should there be TWO pins (noted by the red arrows) within the space of the "Gear Shift Plate" #19 on the Ron Ayers microfiche. (highlighted by the yellow bracket?

I saw that mackey's had one pin in that space.

or do they alternate, and sometimes you have one pin in that space and sometimes 2 pins?

thanks

2737598-img_5079_2_.jpg
 
TWF said:
you can'tput star wrong,it has 2 pins on back that are offset and fit in holes.there is only one way star can go on.
two things that might be wrong in your case.first is make sure that circleclip is on shift shaft where shaft exits case on left side.if not on properly shaft will move in and out in which case it can hit back of clutch basket or/end slip of off the star.
second thing is arm with detent wheel.there is 4 parts here,spring,washer,arm and bolt.bolt has shoulder.when installing you have to make sure that washer is up and around shoulder of bolt when bolt is tightened.if not arm will not move freely and nothing will stop star from turning to far.
Click to expand...

Zoran...i'm going to check this part. not sure if I'm missing the washer. is it supposed to be attached to the bolt? if not, then I might not have it on there. dammit.

the snap clip on the left side was on properly. there is about a mm's worth of play, if I pull on the shift arm from the left side.

back to the detent arm, the spring, and bolt...and washer......i'm seeing that I may be missing the washer.

back to the garage. will post more when I get it.

thanks in advance.

2737603-img_5092.jpg
 
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