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99-04 SV650 05 Shift Kit Installation

glf said:
(snipped)

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
Click to expand...

When the trans is in neutral, the bearing on the detent arm should rest in that depression; that's what you're feeling in your foot when you're searching for neutral.

I have my stock '03 star in my hand right now; Zoran's right, the two locator pin-pockets on the back are offset so there's no way you could put it on the drum backwards. Unless you left one of the two pins out (I don't know how easily they come out of the drum).

http://www.ronayers.com/fiche/300_0305/gear_shifting/gear_shifting.bmp

You did have those two dowels (#8) in that drawing, right?
 
thanks for that. yeah, all the pins are in. i put the star on properly, but because it has rotation, while tightening it and when not held by detent arm, i wasn't sure if I needed to ROTATE it, into any one particular spot.

I think I might have solved the issue. going out for test ride.

i believe I was missing the washer that goes between detent arm and spring. found the old one, replaced it, reassembled, and placed the star in a better position and reassembled. took it around the blocck and it seems to shift all the way thru, and no skipping.

also, the circlip on the left side when I just reassembled it, was to far out, and I noticed what Zoran was saying about it making the shifting off. i placed it further in, and it is in place. no movement from the shift arm now. and it seems okay.

i'll report back.

thanks for all the help fellas.

football game to go to now.

:teeth
 
well, it worked. shifts like a dream. i was missing the washer that goes between the spring and detent arm. and I reinstalled the shift star in neutral position.

oh, well, things are working. thanks for all the help.
 
cool, that looks like something i am going to do
thanks for the write up
 
just remember to organize your pieces somwehere, so you don't miss something on reassembly.

it cost me having to dissasemble the case again, and removing the entire clutch to get to the shift star. no biggie. just more practice..

and to update the photo above of the detent arm. as Zoran said. 4 pieces

the spring, the washer, the detent arm, and bolt. in that order.

cheers

2747474-img_5092_2___2_.jpg
 
I finally did this mod, and it works brilliantly. The only thing is it is really easy to misalign the clutch basket with the oil-pump gear. It took me two or three tries. If I'd been in a hurry, I could have easily assembled the whole thing without the oil pump properly meshing with the clutch basket, which would have resulted in a blown motor.

Cheers,
dp
 
did you locktite the allen head bolt that holds the shift start in place? cause in due time it can become a bit loose, and then come off, which would wreak havoc on the internals. it will show up as an inability to shift the bike.

ask me how I know. :laughing luckily I pulled the cover off, saw that it was loose, and is why it wouldn't rotate the shift star, hence not shifting the gears.

for the record, it was about 1 yr after I did the mod that that happened. and it was probably my error on install. :teeth a quick bit of blue locktite, retightened and good as new. very smooth shifting with this upgrade too.

cheers
 
canyonchaser said:
I finally did this mod, and it works brilliantly. The only thing is it is really easy to misalign the clutch basket with the oil-pump gear. It took me two or three tries. If I'd been in a hurry, I could have easily assembled the whole thing without the oil pump properly meshing with the clutch basket, which would have resulted in a blown motor.

Cheers,
dp
Click to expand...
next time just turn pump gear little while holding basket.
 
Great writeup, I think I may try this after the next trackday for my 1st gen.
 
machete said:
did you locktite the allen head bolt that holds the shift start in place? cause in due time it can become a bit loose, and then come off, which would wreak havoc on the internals. it will show up as an inability to shift the bike.

ask me how I know. :laughing luckily I pulled the cover off, saw that it was loose, and is why it wouldn't rotate the shift star, hence not shifting the gears.

for the record, it was about 1 yr after I did the mod that that happened. and it was probably my error on install. :teeth a quick bit of blue locktite, retightened and good as new. very smooth shifting with this upgrade too.

cheers
Click to expand...

Thanks! I don't remember specifically putting loc-tite on there. Next time I have the oil out of the bike, i'll slip it all apart and make sure! thanks!

dp
 
TWF said:
next time just turn pump gear little while holding basket.
Click to expand...

I actually did slight jiggling of the clutch basket and it all slipped together. The indicator that clued me in was that the center bolt didn't have any threads protruding past it as in this photo (and how it looked when i took it apart).

2493891-img_0173.jpg


dp
 
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