sloppy gearchange fix

[djc]

This might be a widely known fix that I have just discovered - but it does seem to be a good 'un.
The stud/bolt into the lever ball on mine was sheared (a very common problem until Suzuki did a beefed up fix I believe, early 90's?) and the result is very vague gear selection.
I spoke to my nearest Suzuki parts dealer (1/2 hour away) who needed me to go in and i/d the part on screen, then order it, then go in again to pay and collect. Very tedious indeed - then I was chatting with Ray this morning about manifolds and stuff and mentioned my problem.
Ray's fix is to take an M8 20mm bolt (best steel you can find). Screw it all the way into casing til it is locked firm. Centre-mark top centre on the exposed thread. Extract bolt and file or grind flats opposite each other keeping centre mark centred between 2 flats. Check clearance in slot in lever ball, and allow a little play. Also cam those flats a tads to allow for lever movement left/right (1st - 5th positions). But a snug fit gives snug gear changing. Lock bolt back in place into housing and check lever goes back nicely and moves free (not sloopy mind). Grease it all up and refit.
The amount of meat supporting the flatted bolt end is considerably more than on the proper part with turned spigot, so with reasonable handling this should last well - I don't thrust the lever around but like to feel it in so it should hold up nicely.

Neat I thought, quick too - and my gear selection is really good now. Thanks to Ray for the tip.

[ScottieJ]

I've done similar before. I personally wouldn't use him for anything though, the quality of workmanship is not to a good standard. I have one of his su inlet manifolds.....never again, I've had to fix it a few times now, rockwatt's are loads better.

[Anton]

I have one of his su inlet manifolds.....never again, I've had to fix it a few times now, rockwatt's are loads better.

I'm really surprised you didn't mention this complete mess, considering how much work you had to put in to fix someone else's "work"!

[djc]

Hadn't seen that Anton, but I got a bullbar from Ian which came off that truck. I know Ian sold it to me believing it 'like new' and it looked it. Once I got the claggy white paint off (to turn it black) it was riddled with holes and filler, sounded like a pair of maraccas too. I reckon the fact it would fold to the touch was meant to be a pedestrian safety feature.
I am liking my precise gear selection though :)

[Jordi]

I went to Suzuki about £3 i think.