Brake lever and gearshift lubrication how to ( Also installing GMan bushings) - Page 2 - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #11 of 12 (permalink) Old 04-29-2014, 11:16 AM
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I noticed that even fully tightened down, my shifter has a little side to side play on the bushing. Mine's a 2008.
Looking at the OEM partsfinder, and also in these pics, the 2009 and up have "wave" washer instead of just a flat washer like mine has. I think this would take up the extra play and rattle mine has.

So has anyone retrofitted an older shifter with the newer washers?

Also, I only have a single washer behind the nut side. Your's looks like it has both a flat washer AND the wave washer. Where does the wave washer go. Between the nut/bushing, the bushing/floorboard mount, or the bolt head/floorboard mount? EDIT: OK, I see that wave washer has to be beside the bushing to do any good, but which side?

2008 C50

Last edited by GrapeApe; 04-29-2014 at 11:35 AM.
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post #12 of 12 (permalink) Old 05-01-2017, 11:23 AM
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just greased my shifter today, everything went well except for the small nut that goes onto the shifter rod that sticks out the chrome casing. I almost lost it there, after an hour of fiddling around with it, I was so close to dump the bike in the next ditch .... but just a second before I gave up I somehow made it and realised what I think was my mistake. I pushed the nut all the way back onto the rod and couldn't get the screw to screw in, but I guess the way it's supposed to fit is not to push it all the way back - then the screw went on easily. I think there are two different sizes of teeth on the rod, the bigger ones in the back coming out of the chrome casing and smaller ones on the outside end ...

I hope my text is somehow understandable.

And of course after taking the shifter off and put in back together for hundreds of times, as soon as "problematic" screw was back in place I reinstalled the bushing the wrong way around ....

But at least I know now.

Oh and before I forget: after 8 months my shifter was shifting perfectly fine but my bushing already has scratches, I think thats due to the fact that I unfortunately got the left side sprayed in salt while towing it to the garage last November ...


Just came back from the test ride: Does indeed shift smoother now, there wasn't a lot of grease in there to begin with. (Guess they didn't grease it at the 600mile service).

Last edited by alex_at; 05-01-2017 at 01:16 PM.
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