05 Shift Kit Install on 99-04 SV

[stingray]

UPDATE:

use this how-to instead:
http://www.socalsvriders.org/forums/showthread.php?s=&threadid=23293

[Dominus]

Very good write up. Perhaps I'll try this on my 03. I'll post differences if I see any!

[stingray]

awesome, i'd like to see what, if any, differences there are. i suspect maybe just the clutch/side cover removal would be different and the internals the same.

[SVNerd]

Why don't you post it on this site too ?

Far less expensive than the Factroy Pro product.

[stingray]

easier to link than post ;) that and i can keep the resolution of the pics relatively high

that site doesn't require any login, just click. (that and i'm a moderator there so i can do whatever i want to it :grin: )

i tried it out this afternoon, very nice. feels like it's shorter between 1st and 2nd, like i can do a clutchless shift betwn. the 2. i'm gonna try it out this coming trackday and see how it really fairs.

[johnnySV]

werd over here too... yer everywhere moto-brotha !!

[stingray]

can't get enough of SV's you know ;)

[Dominus]

Ordered the parts today...

[stingray]

cool, post up any difference you find :)

[stingray]

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.

also only difference i saw from an 03+ is that you remove the entire side cover since it's an integrated piece rather than a seperate clutch-only cover that the 1st gen's have.

btw, for those too lazy to click the link before, i cut/pasted the how-to and hosted the pics on another server (thanks dave!)

[killstealer]

Would you say that this mod has universal benefit, or is it suited more for a particular riding style (i.e. racing)?

--

Absolutely stellar write up!

[sdlnxgk]

Originally posted by killstealer
Would you say that this mod has universal benefit, or is it suited more for a particular riding style (i.e. racing)?

--

Absolutely stellar write up!


Just what I was about to ask, is it for the "Average Joe" ?? or the "Track Racer"??

Well did some light google searches and found the makers of the Factory Pro Kit... Ya it's expensive so good write up and a great savings.. but gives you some insite if you were like me and didn't know what the kit really does!!

http://www.factorypro.com/products/Factory_Pro_shift.html

Just think with the money you save on the Factory Pro Kit you can get a nice cover with a slider built on it to help crash protect your SV...

http://www.factorypro.com/products/covers.html

This mod is going next on the list with the R6 throttle mod, right after I get tires and braided steel lines w/ new HH brake pads ;)

[killstealer]

Thanks SVJim, should have thought of that myself!

--

Driving in flip-flops? The STAR is a "must have"!
:lol:

[J.Moto]

Originally posted by stingray

9. there are 2 ways to pull the shift shaft out. either from the shifter side, or from the clutch side.

9.1 from the shifter side, there's a circlip and a washer. 10mm bolt holds the "knuckle" and linkage to the shaft. remove the bolt and pull out the knuckle. there's probably gunk all over the circlip so clean it up a little bit get your pliers out and remove the clip.

9.2 from the clutch side it's basically the same thing, circlip holding a washer and spring. same procedures as 9.1.



So for 1st gens, to replace a shift rod/shaft, you just have to pull a side cover?

If so, that's good to know, because I was thinking from the shop manual that you have to pull the motor...

[Dominus]

Got all my parts in to do this mod and I'll be performing it either today or tomorrow. I'll post pics on my experience. Stand by all.......

[twf]

Originally posted by supaPhatty J
So for 1st gens, to replace a shift rod/shaft, you just have to pull a side cover?


yes.

[J.Moto]

How is TWF so smart?!

Thanks for the verification!

[Kurt'sSV]

Originally posted by supaPhatty J
How is TWF so smart?!


He's not a product of the California education system.

[twf]

yea,different kind of education,that is it :)

[J.Moto]

LMAO that pic is funnee!

[Punkbrad]

whats up with those clear window clutch covers? i like those. do those serve a purpose? or are they just bling?

[stingray]

just bling

[illustr8dman]

Originally posted by SVJim
Just think with the money you save on the Factory Pro Kit you can get a nice cover with a slider built on it to help crash protect your SV...

http://www.factorypro.com/products/covers.html

This mod is going next on the list with the R6 throttle mod, right after I get tires and braided steel lines w/ new HH brake pads ;)

Uhhhmmm... Not actually, I wish they did but they don't make these covers for 2nd gen Sv. Great product for those that have the 1st. gen, but sad for those who don't like you and I.

[Punkbrad]

Originally posted by stingray
just bling

perfect! i totally want one. whats the "real" name for that thing?

i saw the guy who put one on recently here on the site, but i cant find the thread..

[stingray]

2nd gen has an integrated cover so no bling factory clutch cover for you guys ;)

not sure on the cover name, AFAIK, they were originally made for the TLR/S so try tlplanet.com on the skinny. i saw it "in action" looked kinda cool seeing the clutch spinning around in it's own juices.

[Punkbrad]

Originally posted by stingray
2nd gen has an integrated cover so no bling factory clutch cover for you guys ;)


Thats beat, thanks anyway Sting - Whats integrated about it? if you dont mind all the questions!

:D

PB.

[Kurt'sSV]

Originally posted by Punkbrad
Whats integrated about it? if you dont mind all the questions!

PB.

Integrated meaning what covers the clutch plates and the water pump is all one piece. On the first gen bikes you can take off just the clutch cover or take off the whole cover to get to the water pump.

[Dominus]

Originally posted by Kurt'sSV
Integrated meaning what covers the clutch plates and the water pump is all one piece. On the first gen bikes you can take off just the clutch cover or take off the whole cover to get to the water pump.

Yep...
Just did the mod last night. The whole right side cover has to come off, which also includes removing some bolts for the water pump...thus you have to drain the coolant to facilitate the job. Other than that it's all pretty much the same. I'll post pics up later.

Oh, and don't forget. If you're working on a second gen bike you'll need a different gasket than what's listed in the first post. Perhaps that could be added to the beginning of this thread.

For an 03, you'll need the gasket part # 11482-17G00.

[Enchanter]

Originally posted by stingray
For those who don't know, the 2005+ SV's shift mechanism is basically the same as the factory pro kit, ball bearing instead of a bushing, more "aggressive" star w/ bigger lobes and a stiffer spring but for a fraction of the cost (i think it costed under $50 incl. shipping for all the parts vs. the $200+ for the factory pro). if you wanted to go for an even smaller budget, just get the spring and the detent arm.

OEM P/N#
25381-19F10 (shift star)
25350-35F00 (detent arm)
25355-35F01 (spring)
11482-19F00 (clutch side cover paper gasket)

thanks

Its an old thread i know that but im curious if you have noticed and differens after you made that mod for your bike? Did it change gears more easier, "drop" gears to neutral is no more?

I have som gearing problem with my SV from ´00, it demands som force to make it change gears which dont feel so fun ..

Would be glad if you could tell me!

/Daniel from sweden

[stingray]

no false neutrals or mis-shifts for me after the mod

[Kurt'sSV]

Yeah, no popping out of gear for me, either.

[svlobo]

Any alternatives to using the factory clutch sleeve hub holder? I haven't torn down yet , though am starting, and I'm concerned about not having the factory tool. TIA.

[johnnySV]

if u have access to the equipment, its pretty simple to weld one up.

otherwise maybe u could nut/bolt something together out of barstock or angle iron

[stingray]

it's $30 or so for a motion pro clutch holder.

[svlobo]

I used a BAS (big ass screwdriver) and it worked fine. I ran 2 of the clutch bolts in to add strength to casting and torqued to spec. If it were much more I would've been more concerned but the 'work around' seems to have accomplished the goal. Thx.

[patriot_missile]

I just did this mod on my 02. Pretty simple mod. Although I had to take the entire shifter shaft out of the bike because the return spring was broken which requires to take the whole side case off but it should be taken off anyway to make this mod easier and less of a hassle. I rode the bike today and it has a more sound shift to it and it's very easy to shift. Two thumbs up on this mod!

[Hopwheels]

Just got my parts in for this... hmmm do I want to risk missing the Sunday ride, 'cause I mess something up on the bike tomorrow?? NOOOOOO. I'll be waiting, but I'll get into it soon.

PS: Anyone know where to find a '03+ walk-through on this project? Thanks!

[Surferfeet]

After my last track day my sv1ks sat for about 2 month and now that I'm riding it again, it's back firing through the air box sometimes but more so through the exhaust.
I've cleaned plugs and ran fuel injector cleaner without success...short of a fuel injector service, can anyone suggest anything?

Thanks

[nefarious-az]

Originally posted by Surferfeet
After my last track day my sv1ks sat for about 2 month and now that I'm riding it again, it's back firing through the air box sometimes but more so through the exhaust.
I've cleaned plugs and ran fuel injector cleaner without success...short of a fuel injector service, can anyone suggest anything?

Thanks

This has what to do with an 05 Shift kit install?

[SVNerd]

Originally posted by nefarious-az
This has what to do with an 05 Shift kit install?

:lol: Exactly what I was wondering ...

Hopwheels, as for knowing where to find a '03+ walk-through on this project, yeah - my house. Did it on my '03 - and further complicated the project with the install of a slipper clutch ... but I digress ...

You'll have to remove the clutch - do you have the tool to hold the basket ?

[Hopwheels]

Hey SVNerd... I have a cheapy clutch holder (I tweaked the crap out of it on my older bikes, it's nothing more than a hunk of metal to wedge into the clutch basket somehow now), and a leather strap wrench (not sure if this'll work, I got it to help hold magnetos for torqueing), so short (too late) answer... NO, but was going to go pick up a Motion Pro vice grip type.

So since you've been down this road, can I know this out in a few hours? Any major non-obvious dos and don'ts? Thanks!

[SVNerd]

The Motion-Pro tool is not as nice as the "vice" type, but worth the money - I have one, it works fine for the job. Either get one, or come over and use mine (for free).

It doesn't take that long, and I personally waited until I need an oil change ... and I was also ready for coolant replacement (Distilled and Water Wetter).

I drained the oil into a clean container, then re-installed it afterward. After confirming that everything was working well, no leaks, etc., I changed the oil and filter. This way, you flush any dust, etc. into the filter, that may have gotten into the engine in the process.

The initial removal of the parts and installation of the "star" cam (with detents), the ball-bearing follower, and spring are pretty trival. That took less than an hour.

As you likely know, properly re-installing the clutch is critical, so try to keep the plates, spacers, etc. in the same stack order as when you remove them. Saves some serious head-scratching on re-install.

The process is kind of fractured in the factory service manual (in Chapter 3 Engine) - but it does cover everything pretty well.

Perphaps obvious, triple check everthing before re-installing the cover !

The trickiest things were the placement of the NEW cover gasket and the proper seating/orientation/alignment of the waterpump/shaft. Not bad - just don't force anything.

After everything is re-installed, you should re-adjust the clutch - it may not need it, but worthwhile to check.

If it takes more than 4 hours - something isn't going right ... too many beers involved ... honey-dos getting in the way ... I wish you well with it !

[Hopwheels]

too many beers involved
Damn, that's always my problem (or solution) on bike projects...

Thanks for all the tips... I like the idea of recycling the used oil, then doing the full oil change. Good call. So I got a 50/50 premix, aluminum-friendly coolant. OK, or go the redline water wetter route? (no trackday plans for now).

Did you use a paper gasket sealer, like gaskacinch, on the cover gasket, or is one needed?

[SVNerd]

If you're using a 50:50 pre-mix on the coolant, I'd go with the OEM Suzuki. I've read a number of mixed (no pun) experiences with folks using automotive coolant (if that's what you're planning to use).

Its a little cooler in Fallbrook than here in the winter ... (it freezes on occasion - no ?) soooooo if you aren't doing any trackdays, no real need to switch. If you're considering a track day before next winter - now may be a convenient time to switch. WaterWetter and distilled is fine for summer, even in Borrego.

No sealer needed if you use the Suzuki OEM gasket. No leaks several thousand miles later ... there are some pretty cheesy aftermarket gaskets Iv'e seen, that I'd definitely use a sealer with.

Try to pace yourself on those beers for this one :D

[Hopwheels]

Try to pace yourself on those beers for this one

Perhaps the most sage advice...

[Enchanter]

I just want to say that i also have installed the 05 shift kit and it works great! It have lots more feeling now when changing gears and no popping out of gears to.

Thanks you guys for giving me this mod!! :)

[SVNerd]

Originally posted by Enchanter
I just want to say that i also have installed the 05 shift kit and it works great! It have lots more feeling now when changing gears and no popping out of gears to.

Thanks you guys for giving me this mod!! :)

Cool.

How many beers did it require ?

[Enchanter]

Originally posted by SVNerd
Cool.

How many beers did it require ?

I took alittle brandy during the work :D
But it wasn´t hard to do, thanks to you guys :)

[Hopwheels]

Thanks for this really great write up. And for the extra info SVNerd. I just finished up my install last night and took my bike out for a spin around lunchtime today. It really does make a difference. My upshifts seem way smoother. BTW, I was too stressed that I was going to mess up to enhance my wrenching abilities with alcohol last night, but I'll make up for it another time :D . (So I don't know how many beers this project should take.)

Also ran into (well he actually ran me down) Aaron on his way to work while I was on my little, "did I screw up my bike," run. That was cool. Guess we need a "TL Sightings Thread"! He had to pull in front of me and signal to get my attention... didn't know who the heck it was at first... Nice chattin' with ya' Aaron... sorry you had to head to work...

[DasTeufel]

Glad to hear your shift kit worked well! I didn't think you recognized me at first lol. How was your ride? I had a fun ride to work, two coworkers rode in with me from Bonsall (one has a DRS, the other a ZX10).

[Hopwheels]

Cool. Now on to the ss front brake lines... man I hate doing brakes... I always manage to get that crap everywhere...

[SVNerd]

Glad it went well, and that you're pleased with the outcome.

C'mon ! If you don't already have them, get yourself a Mighty Vac and some Speed Bleeders, and you'll never spill again.

In any case, helluva lot more trivial than the "shift kit" upgrade.

Back to the regularly scheduled program.

[Hopwheels]

I do have a Might Vac... no speed bleeders though... and I still get the stuff everywhere... ergghhhh... that project will have to go w/some brewskis for sure...

[g.i.bro]

get the speedbleeders..... they are amazing....... that and some tubing and brake bleeding takes meer minutes and no spills

[SnowyAK]

I just purchased the parts for this mod, I hope it goes well.