How To: 05 Shift Kit Install on 99-04 SV

[stingray]

http://www.bayarearidersforum.com/forums/showthread.php?t=189382

[stingray]

updated to new version. should be easier to follow.

[summitsix]

Are you MackeyStingray from BARF?

[Kurt'sSV]

Originally posted by summitsix
Are you MackeyStingray from BARF?

No. We don't let dorks like him on this board. :p

[stingray]

:grin:

[The SV FNG]

Originally posted by Kurt'sSV
No. We don't let dorks like him on this board. :p

:lol:

[J-Mar]

Nice. . . . . I have a second gen so this doesn't apply to me, but I had to say something about the 'shocking' reflection off of the clutch cover in the first pic. AWESOME!

[SVNerd]

Originally posted by J-Mar
Nice. . . . . I have a second gen so this doesn't apply to me, but I had to say something about the 'shocking' reflection off of the clutch cover in the first pic. AWESOME!

Its does apply 2nd gens of '03 and '04 vintage ... (not yours).

[Som]

I've got the Factory Pro shift kit without the shift star on my bike.

I want to buy the star... how much of a difference is there between the Factory Pro star and the '05 star? (has anyone either tried both or held the stars up to each other?)

- Som

[Darth Lefty]

What exactly is it that this does for you?

[SVNerd]

Depends on which version of the Factory Pro star: the original kit (with star) was a substantial improvement over the OEM version (through '04).

The original Factory Pro kit improved shifting, particularly hard shifting under high load conditions (full throttle, track, racing, etc.). Far fewer missed shifts and false neutrals, but required more force at the shifter - less ambiguity in engagement.

For '05, Suzuki took matters into their own hands, with a new star geometry (detent follower was also improved, and spring rate changed) which resulted in many of the same qualities that the original Factory Pro star had - with less force required for engagement.

Factory Pro now has a 2nd version of their star, which exhibits the qualities of Suzuki's improved star, but with more positive engagement.

Factory pro has an "upgrade" version of the new version kit, if you had an original ... I think its like $130 or something.

[Som]

Yeah, it's $130... but supposedly this '05 alternative is much cheaper (I thought I read someone saying it was $50 for all 3 parts). I'm wondering, if the difference in price is that great, if the extra money could be worth it.

I had *several* drops to neutral after dropping from 3rd to 2nd and twisting the throttle... then, to cap my day off, in the last session the bike actually switched gears as I went to accelerate! Back end chirped, grinding noise, tank slapper, and me almost over the handlebars in the middle of turn 3.

The explanation of the problem was that apparently after a lot of wear and tear that the shift star gets ground down so the peaks round off and aren't so sharp -- which results in the slipping to neutral.

This explanation seems to make more sense if the higher spring rate of the detent spring actually results in more wear on the shift star... since I have the higher detent spring from the Factory Pro kit, but the shift star being the stock '01 shift star -- maybe it's ground down quite a bit over time.

All I know is that the bike shifts so smoothly that I never got a good feeling for which gear I was or when I had actually engaged the gears.

- Som

[SVNerd]

Tank slappper ? From shifting ? BTW - you have a decent steering damper on that thing ?

Wear on the star is insignificant - even after 50K miles: there's hardly any load on it, and detent follower is a wheel (with bearings). The star itself is hardened steel ... so I don't buy the "explanation". I'm suprised you do - take a look at the assembly photos in this thread: that follower wheel is the only thing in contact with the star - and with only a minumum of force.

Up through '04, it has more to do with the shape of the star. I assume that Suzuki didn't anticipate the extreme use of the SV that its so successfully been put to. It works fine for lazy shifts when slowly accelerating in traffic. Start banging on the shifter at the track - and it behaves exactly as you describe. Obvioulsy Suzuki was compelled to make improvements.

As for the springs - I checked the torques on them once, and foolishly didn't record the results ... and can't remember ... but what I recall is that the Factory Pro spring was greater than the Suzuki '05-up version ... please don't hold me to this though ...

Go with the '05 up bits: try it. Less than the race tire/gas cost for a single track day. :D

If you don't like it, buy the Factory Pro star (which I personally really like !) - and sell the OEM Suzuki bits. Someone will buy them.

There is another problem on some SVs (more common up to '04): centering of the star on the shift shaft. The indication is that star's pins aren't centered between the fingers when the shift shaft is at rest. Factory Pro offers a fix for about $25: an adjustable center shift stud. Of note - long ago - bikes used to come with these.

I also want to note that its been my experience that the inceased mechaincal precision of better quality rear sets can compound (amplify) shifting problems (if you have them to begin with).

Lastly - if you're not doing it already, I suggest keeping a notebook foryour bike and track/race days. Record setup details/changes, temps, humidity, elevation, and your ride experience. I occasionally bring a laptop (which doubles a tuning tool). Ask anyone on who races: even if you're fast enough, consistency is everything.

[stingray]

shift forks, not star would wear out if anything

i get my parts from flatout. despite some people's bad experiences (w/ their aftermarket parts man who's since been fired) i've always had good luck w/ them.

http://www.flatoutmotorcycles.com/fiche_section_detail.asp?category=Motorcycles&make=Suzuki&year=2005&fveh=10157

go to gear shiftin K5 on the drop down menu select the P/N you require (about $35-40). for you G2 owners, you need to paper gasket as well in which case, select crankcase cover in the menu and select #3 ($9-10)

[Som]

Ordered. Let's see how it goes! :)

- Som

[Darth Lefty]

I've been riding mine this way for a while now and it's definitely way notchier. Takes a harder whack to move it, and snaps into the next gear more eagerly. I'm not convinced I like the way it feels but it does seem to shift a lot better. Fewer blown shifts and I was having an occasional false neutral between 4th and 5th that I haven't seen since.

I tried doing it by just taking off the clutch cover but lost the washer off the shifter rod in the oil sump. (And I was messing with that, because the real reason for being in there in the first place was to replace the return spring on the shifter rod which had broken, and this upgrade was just a bonus because it was convenient.) I had to take the side cover off anyways to find it, and the gasket tore, and then there was some fun fishing around with some steel wire and a magnet. So don't forget the side cover gasket when you order parts or you could be sitting another week... even if you plan to do it the other way.

Oh and finally, instead of the clutch holder tool to get the nut off, I put it in gear and put a piece of angle iron through the spokes on the rear wheel. This dinged the wheel a little and it puts some pretty good stress on the drive train. There may be some other reasons it's a bad idea.