Today it started….snowing that is. And not only did is snow, but it stuck. I scraped snow off cars at the lot today, and I was cold. Today, was a very depressing day for anyone who rides motorcycles. It is the beginning of six months of being deprived of a beloved hobby. Well today didn’t turn out to be too bad for me anyway. Today was the first day for my replacement at Market Motors. His name is Eric Faux and I believe he will do a good job at the lot. This means a lot to me since I will not be working there anymore and I want the lot to do well. Yesterday I interviewed about 20 people trying to find the right person to work at the car lot. Of those 20 people I talked to maybe 3 were remotely close to being ‘THE’ person for the job. I do have to say that being on the opposite end of the interview was nice, especially being on the interviewee end for the last 6 months. I will miss working at the car lot, and I can not forsee that I will not be out of the picture of the car lot since my father-in-law owns it. I am looking forward to working at The Tire Rack and I can now feel good about making this decision to move on in careers.

Looks like someone from GlockTalk.com found my 2002 Glock Armorers Manual that I scanned in last January. I had been searching forever for an updated glock armorer’s manual and broke down and finally bought one off of ebay. I have been getting a decent amount of referrals to my pdf file. Keep them coming! Maybe I can kill the demand for the bastards on ebay that are trying to sell this file for a profit. If you came here looking for the file then check out my Downloads Section

7/23/04 Purchased SV650s in Athens Ohio with 2563 Miles. Bike has a full system Yoshimura Carbon Fiber pipe. K&N Filter, and jetted. Also has an unknown fender eliminator kit, a Dunlop Rear Tire, and the original Metzler front Tire. $3800

8/23/04 Purchased Motosliders full set including rear swingarm $95
9/15/04 Purchased Magknight Tank Bra and install it. $86
10/5/04 Purchased Corbin Seat for $150
10/5/04 Purchased Rear Seat for $35
10/15/04 Modified Rear Seat to carry a duffle bag

4/12/06 Start season with 7500 miles
6/15/06 Replace Brake Fluid and oil 8500 miles
7/15/06 Purchase Tank Raisers .8 inch $15.00
7/18/06 Purchased Michelin Pilots $130 rear + $98 Front 9500 miles and replace oil
8/15/06 Purchase xtreme camera tankmount $95
8/20/06 Purchase Throttlemeister Throttlelock $127
8/22/06 Purchase Alpinestars Dyno Jacket and Bat Pants, and SP-2 Gloves $550
8/31/06 Replace Oil and Filter, Clean and Lube Chain 10433 Miles

Carriage Bolt Gear Selector Repair For SV650

Introduction:

So somehow the gear selector “foot” has snapped off your SV650. Could be someone tipped it over and you didn’t have frame sliders or some other mishap. Now Suzuki is beckoning you to spend 60 dollars to buy a new one! Well, with a bit of work, and assuming your selector pedal is not too bent or broken at the wrong spot, you can use a carriage bolt to fix it for about 5 – 10 bucks, depending on the tools you already have! Basically we are going to drill out a hole for the bolt and tap it with threads and then thread in a carriage bolt! Simple! I’ve got some pics for you to use as a basis for your own fix. Is it easy? I did it in my kitchen with hand tools, so yeah, it’s pretty easy.

Disclaimer:

This is simply a listing of the steps I took to fix my broken gear selector lever. I’m not a mechanic nor do I claim to be. I don’t know how robust this fix is so be careful. I’m sure that if you drop the bike, it will break again. Keep in mind that this repair may fail on you while you are riding, so I suggest you read it through and decide for yourself if you want to do it.

Installation:

This is what I did, you may want to do something else, but this worked and you can use it as an idea. Read through before attempting anything. If you screw it up, go buy an OEM part. The thing is that the lever is broken already, so breaking it more is irrelevant.

Tools:

You’ll need to remove the gear selector pedal from the bike, and you’ll need to operate on the bike

Hex keys, not sure what size, but they come in your tool kit, so everyone has one.

adjustable wrench

locktite/threadlocker

17/64 inch drill bit

5/16 inch carriage bolt and nut, I used a 2 inch one but had to cut it a bit since my lever was bent a bit

5/16 inch tap (A “tap” is used to create threads in the hole)

tap handle (or not, I accidentally bought the wrong size and ended up using a wrench)

C-clamp, or a vice vise

Optional JB Weld

Step 1:

Remove the pedal/shift lever assembly. First loosen the lever adjusting rod.

IMPORTANT: the buts circled in green are LOCK NUTS, this might be obvious, but I was an idiot and turned them the wrong way. Simply turn them such that the nuts go towards the center of the rod. When that is done, you can just rotate the rod until it comes off!

The bolts circled in pink are hex bolts, remove them and the assembly should come off the bike.

Step 2:

Using a 17/64th inch drill bit, drill out the part where the shifter “foot” was. Note that I used a hand drill.

(This hand drill belonged to the guy who stole my old bike and abandoned it in the saddlebags as the cops arrested him!)

Step 3:

Tap out the hole using your 5/16th inch tap. I bought the wrong size tap handle, so I used an adjustable wrench instead. Hey, it worked, so what the heck.

Step 4:

Remove the rubber “boot” from the original shifter foot, if you still have it.

Take the 5/16th carriage bolt, and put the rubber boot on it. If you lost the boot, I’m sure that wrapping the bolt in electrical tale might work, or better yet, a huge glob of JB Weld/Epoxy. The boot fits nicely!

Thread the nut onto the bolt (not shown on this pic) , you may want to put some threadlocker (or JB Weld) on the threads. This is your new shifter “foot”

Step 5:

OK, now thread the foot onto the lever, again you may want to put threadlocker on it, or JB Weld/Epoxy. Lock the nut tight against the arm.

Now for me, I found that this bolt was too long, so I took a Dremel to it and cut it down a bit, because my shifter arm was bent a bit such that the bolt extended too far back. I could have simply added another bolt to the “foot side” to make the foot longer, but I cut off the excess instead.

The lock nut is pointed to by the pink arrow and the excess that I trimmed is shown in green, you can see that I could have simply put another nut next to this nut. Maybe that was a better idea, since it would lock down the first nut good. I chose to saw off the excess because I didn’t want the foot too long, it might make it more breakable;

Step 6:

This is optional, but I globbed JB Weld/epoxy onto the back end of my lever and smeared it on the exposed threads and the nut to lock it in place and to “smoothe” out the extended part so it wouldn’t catch on lever adjusting rod. (Yes this picture sucks. JB Weld resisted all efforts of my camera to focus on it. I think the stealth fighter’s secret is that it is coated with glue)

Step 7:

Put the lever back on your bike! Make sure to use threadlocker on the shifter assembly bolts to prevent them from working loose! You are now done. I didn’t bother with pics, because it just looks like a normal SV shifter lever!

This page is a mirror of http://www.mindspring.com/~vlok/SV650/Gear_selector/gear_selector.htm

Sunday was extremely hectic and our day was consumed by visiting people and taking care of odds and ends. We opened up all of our presents and cards and toted them all back to our house. A big THANK YOU to everyone who gave us gifts! We then visited our pastor who married us and he signed the marriage license, went to Katy’s moms house to get some things, went to Brian’s to pick up our gift, and traveled all over Elkhart taking care of odds and ends. Katy then went to hang out with Dave and Kiarin the Australians and I rode my bike with Brian.
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