Clutch Is back together now Shifting Problems

[Netter]

Ok everyone sorry for the delay and lack of pictures but Im asking questions from Michigans U.P. and my bike is WAY downstate being fixed so pictures might be hard to get as my dad tells me that you cant see what it is in a picture (so I have NOT seen the problem). quick recap my clutch did look like this viewtopic.php?f=8&t=1200 now it is put back together with all new plates and shifts while the bike is off

The Problem:
you start the bike in neutral go for a ride and get it into all the gears you stop the bike and you can't shift it into neutral (It is super hard) you have to turn it off to get it into neutral also when the bike is on you can't shift through the gears it goes up to second fine then gets stuck at third.
So bike shifts fine while riding, when stopped doesn't shift

my dad took the cover back off and said that there is a spring at the end of the shift rod (away from the shifter pedal) there is a 'c' bracket that actually shifts the gears
he says there is a small spring (like a millimeter thick) and he does not know where it goes he thinks it applies pressure (but I'm not sure if it a spring that gets pushed down on or pulled out)

Like I said the bike is at home and I am at school so I haven't seen what he is talking about Im just hoping to figure it out, If anyone can help or direct me to a previous post any help would be most greatly appreciated, I'll try to get him to send me some pictures also to get up here

[the_finch]

I have my clutch taken apart at the house, and I have ALOT of pictures (working on a write up for the Wiki), I'll see if I can't post a pic for you tonight when I get home so everyone can visualize a little better.

[Netter]

Awesome thank you Ill see if I can get him to take pictures also

here is a picture with the location - its not a good picture it was taken with his phone
he said that the screwdriver is holding up the spring




UPDATE!!!!!!
when the bike is OFF it does not shift well first and neutral are ok but going to second does not work well if it goes to second then going to third is not going to happen

sorry for not having a more straightforward problem description its tough not being with the bike

[Netter]

Ok so after looking through the manual on the top of page 4-61 it says check : shift pawl position, gaps (a) and (b) are not equal replace defective parts or adjuster
where is the adjuster for that? maybe that will help the shifting problem? any one who as any suggestions would be greatly appreciated

[the_finch]

Just my (and I could be wrong) but my bike doesn't go through the gears either when the transmission shaft doesn't spin. I have my clutch assembly out, and to test to make sure my shifter works, I put the clutch boss (center part of clutch assembly) back on the transmission shaft and lightly spun it while shifting through gears.

Side note: if you remove your clutch (which isn't that hard), now would be the perfect time to inspect the clutch friction plates and install a Factory Performance Shift Kit (about $60) which will really improve the feel of how your transmission shifts.

Also, I know I fell down on the job (been really busy with school+work) but do you still need me to post some more reference pics (like the ones without the clutch installed)?

[Netter]

My dad keeps tinkering and it keeps getting better but more pictures might be helpful, ill get some more updates as soon as i talk to my dad
Thanks for the help!

[the_finch]

Here's some pics, as promised, from the pics I'm taking on a couple of write-ups I'm doing. Hope they help.

Here's one with the clutch still in:

And here's a pic with the clutch removed:

In this pic, the oil pump has been removed as well, but note that the "detent arm" (the one the socket is attached to) is not in the proper position, as I am removing it:

And here's a close up before I removed the oil pump, when the whole shifting mechanism was intact:


Hope those help out.

[mike94fzr600]

i am not sure if this helps but it looks like you are having the same problem i had with my banshee. if that spring is not holding like it should on that CA clip thing it wont hold the gear right and will be hard to shift. when it happen to me i just got a new shifter lever and it worked fine after that. on my the spring had stared a little so it was not holding like it should

[Netter]

Awesome thank you very much for the pictures, that spring is just what he is talking about, is it safe to ride with that spring a little loose? and is there any way to change just the spring?

[the_finch]

Awesome thank you very much for the pictures, that spring is just what he is talking about, is it safe to ride with that spring a little loose? and is there any way to change just the spring?

I would say no. The tension provided by that spring is pretty much the only thing that locks the shift star precisely into any particular gear, and without it, finding neutral is nigh unto impossible. Theoretically, you also run the risk of seriously damaging the transmission if that shift star turns too much in any direction on its own (imagine the transmission trying to be 90% in 2nd gear and 10% in 3rd gear at the same time). While I don't know this from experience, that's what I keep coming up with when I visualize it in my head.

You can change the spring if you want to, as it just slides on and then you bolt the arm back on while holding against the tension spring (I used a pair of needle-nosed pliers) and torque it down. I actually have a stock spring, arm, and bolt lying around now that I've installed my shift kit (it replaces the arm and spring, the bolt is a long, drawn out story). However, I really suggest if you're gonna have the thing apart anyway and will replace the spring, just go ahead and invest in a factory pro shift kit. They're not too expensive (approx. $50) and really help out the shifting. It even comes with a clutch cover gasket, in case yours was damaged in the removal process.

I hope you can get your bike on the road again soon, and once again enjoy two wheel freedom. Good luck!

[YAM93]

Thanks guys, looks like i might join the "Clutch Club" after all.

[Netter]

Ok so you guys sold me on the shift kit, where did you find one for 50ish dollars all the ones I have seen have been 80+?
Thanks again for all your help!

[YAM93]

i think they used to offer something closer to $60 but i can't find it anywhere anymore. The one that's usually $86 at Dennis Kirk comes with the gasket. Best to go that route so you don't have any oil leaks afterwards.

[the_finch]

Ok so you guys sold me on the shift kit, where did you find one for 50ish dollars all the ones I have seen have been 80+?
Thanks again for all your help!

Hey, if you haven't gotten a shift kit yet, here's one that's currently a deal;
http://cgi.ebay.com/ebaymotors/ws/eBayI ... ht_500wt_0