Shifter problem on 93 Quadrunner 250 LT-4WD

[kenikas]

I've got a problem with the shift lever returning to the centered position, and it seems the same either upshifting or downshifting. It goes in to all the gears ok, but does seem a bit difficult to get in to gear sometimes, but every shift you have to tap the shifter with your toe either up or down to center it before you can shift in to the next gear. The people we bought it from had only used it to plow their driveway in the winter for several years, and had only used 1st and reverse for a long time. I've tried lubeing the cable ends and the shift lever pivot, but doesn't seem to help. Any ideas?

[Mech]

I'd take the cable off the engine end and see if the lever on the cases returns to center nicely.

 

[kenikas]

Thanks Mech, yep the lever on the case moves like it should when the cable's disconnected. I disconnected it from the shift pedal as well and the culprit is definitely the cable. I'll try and flush it out and run a bit of cable lube through it and see if I can get it to move smoothly.

[MarkinAR]

If you don't have a cable lube tool, I'd get one.  They are a life saver on older machines.

 

https://www.amazon.com/GTSpeed-Universal-Motorcycle-Cable-Lubricator/dp/B009T3VUK8/ref=sr_1_5?keywords=cable+luber&qid=1643733606&sr=8-5

 

[Mech]

That cable's probably lined with nylon and not meant to be lubed..

Some genuine suzuki cables are surprisingly cheap..

[Mech]

And yeah, if the cable looks ok on the outside(no worn off outer)wash it with water and work it to get dirt out if it doesn't look like it's been oiled. If it has been oiled then wash it in petrol or kero.

[mellephants]

Is the shifter rubbing the plow lever or mount?

On my 93 with manual plow I had to bend the shifter away from the plow mount to prevent it sticking against the plow parts. 

Probably not an issue with a winch operated plow. 

Edited February 5, 2022 by mellephants

[kenikas]

No, it's definitely in the cable. And this one has a winch operated plow. But that was my original thought too, that it was just rubbing somewhere.

[kenikas]

Finally getting around to a follow up on this, unfortunately this machine kinda got back burnered and is still in the corner of the garage due to other carb/ignition troubles. But we did come up with a cure for this shifting issue, this is a nylon lined cable, and the Suzuki replacement is surprisingly NOT CHEAP! So we got a serviceable used cable from powersportsnation, that is much smoother than the original. But it still doesn't always completely center when shifting and we're hoping that when we get it running better and ride it around it will loosen up a bit more. My thoughts are that the internal spring on the shaft is a little weak and that's causing part of it, so we just put a couple of "helper" springs on the foot lever, and that seems to have cured it.

[Mech]

Ha at the surprisingly not cheap..  Hope the second hand one comes right then..