1990 LT-4WD 250.
I bought this as a non-runner. After I made it run I found that it is extremlly hard to shift. In fact I have to use my hand to pull up on the shift pedal. It is also hard to downshift, but one is able to apply more down pressure and shift. I removed the cable from the shifter arm and the cable moves free. I have a Susuki service manual, but am kinda unsure as to what particular piece may cause this problem, or which side cover to remove to look.
With the shift cable disconected I have to use a pry bar to move the shift lever thru the gears, but it's much harder than I think it should be. The reverse lever moves very easy as does the other two levers.
Any assistance would be greatly appreciated, Tom/Idaho

 

The shift lever itself isn`t rusted on the shaft is it?

 

My Suzuki book list the following cause for difficult shifting
1. damaged clutch system
2. incorrect oil viscosity
3. bent shift fork shaft(s)
4. bent or damaged shift fork(s)
5. worn gear dogs or slots
6. damaged shift drum grooves
I have noticed when the choke is on and the RPMs are up mine is hard to shift. Idle it down as low as possible. Hope this helps.

 

Thanks to both of you for your replys. I took off the right side cover and I could shift it with my hand. The previous owner had (for some reason) tightened the clutch adjusting screw way to tight. I put it back together and test drove it. Seems to shift like it's supposed to and does not appear to slip. Time will tell.
Thanks again for your suggestions, I trully appreciate your help. Tom/Idaho