Daniel's Tri-Series Rnd 2

[discodan]

Report is up now here: http://dkempthorne.blogspot.com/

No win this time unfortunately. I had to remove the big bore kit so as not to arouse too much suspicion and it turns out I'm really crap without it

[Deano]

Great report Dan - bugger about the off track excursion and interesting to read about the 'other riders' tactics.

[Robert Taylor]

Report is up now here: http://dkempthorne.blogspot.com/

No win this time unfortunately. I had to remove the big bore kit so as not to arouse too much suspicion and it turns out I'm really crap without it

Daniel, it sounds like your gearbox needs undercutting. This jumping out of gear problem will only get worse and if you want to win the Nats youll have to bite the bullet and get it done.

[wharfy]

Good results (despite the off road stuff) and great write up.

[Shaun]

Disco Duck, check this part out mate

25350-35F00
STOPPER, GEAR SHIFT CAM

They are really bad on the Honda's, and may be causing your problem also, effectively, the part that is supposoed to rotate perfectly, goes of centre causing gears NOT to engage correctly, and it always starts with one gear and then moves on to more off them

[SWERVE]

Good stuff Dan.......... before you go ripping out gearboxs - check the end of selector drum behind clutch basket. The little pawls could have lost there edge and that will cause it to jump out of gear (they are quite cheap) doenst normally damage the drum as it is harder material.
Although most suzukis are known for weak second gears- if you replace also replace the co-reponding gear in the cluster (thinks its 5th) Another thing you can do if you strip the motor is fit a stronger de-tent spring ( some fit two springs but makes gear changes stiffer)
Dont let any old engineer undercut the gears as some processes lose the case hardening and cause even more wear ( spark erosion is a good method)

Good luck and hope you get it fixed as we want you on top form for a national showdown

[discodan]

Cheers.
And thanks for the gearbox suggestions guys, I'll look into them.

[Robert Taylor]

Cheers.
And thanks for the gearbox suggestions guys, I'll look into them.

All good advice from the guys above. It never ceases to amaze me how many production gearboxes rely almost totally on shift drum stopper tension to keep the selected ratios engaged. The correct way is to have a design with undercut on each enagaging set but of course everything is engineered by bloody accountants and the world is so competitive on price that customers get what they pay for!
Given that this model of bike was never intended for racing, that more power extraction loads everything more and that second gear always accepts a lot of acceleration torque its not surprising that the gearbox is one of the achilles heels.

BTW Dan Ive jacked in more ride height. This is compensting for the lazy head angle, not ideal but the frame has to remain standard. The steering damper is now nearly fitted, if you have another off track excursion it just may save laying it down!

With respect to the contratemps with Geoff Im ''in the middle'' as I do work for both of you. Suffice to say there are two sides to every story.

[Shaun]

Hey Dan, I got a reply from a tuner in the USA RE any gear box issues on the SV 650, here is what he said


"Nope. They last forever, basically. I've got 10k hard track miles on a couple. Look elsewhere. "Is your boot hitting the shift rod?"


And being a tall guy riding under a lot of pressure, it is Highly likely that is exactually what is happening
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[discodan]

Hey Dan, I got a reply from a tuner in the USA RE any gear box issues on the SV 650, here is what he said


"Nope. They last forever, basically. I've got 10k hard track miles on a couple. Look elsewhere. "Is your boot hitting the shift rod?"


And being a tall guy riding under a lot of pressure, it is Highly likely that is exactually what is happening
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Good point. I have just put on some new rearsets too.

It was just a bit strange that it was only during the start of the race and not after the first corner so that is a good possibility.
Cheers.

[codgyoleracer]

Good point. I have just put on some new rearsets too.

It was just a bit strange that it was only during the start of the race and not after the first corner so that is a good possibility.
Cheers.

Hi Dan, A good show & some err close racing........ , Gearbox thing is usually the simple stuff & if you have new boots or rearsets - it is real easy (as i am sure shaun will concur) to be a bit over eager changing gears (especially off the line) & not allow the lever to return to the unloaded position which will allow it to jump out of the selected gear sometimes.
SV boxes are pretty tuff - but undercutting will assist when you next have the cases split apart.

Oh - & was that the sun shining out of your arse - or just a psychedelic paint job.....

[discodan]

Hi Dan, A good show & some err close racing........ , Gearbox thing is usually the simple stuff & if you have new boots or rearsets - it is real easy (as i am sure shaun will concur) to be a bit over eager changing gears (especially off the line) & not allow the lever to return to the unloaded position which will allow it to jump out of the selected gear sometimes.
SV boxes are pretty tuff - but undercutting will assist when you next have the cases split apart.

OK, cheers.

Oh - & was that the sun shining out of your arse - or just a psychedelic paint job.....

I was told to paint it that way so when the bike is upside down in the gravel they don't need to use the yellow flags.

[Frenchy]

was defiantly some close racing, i thought you did well mate! cant wait to see how you go at Wanganui good luck