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Tranny/Shifting problem

A

ALB80-850

Forum Mentor
Super Site Supporter
The bike is all back together and running....But, I can't seen to shift into gear without stalling.

The clutch cable seems to be adjusted correctly. While running in nutral on the ground it is fine. When I depress the clutch and try to shift to 1st it lurches and stalls while still holding the clutch in. Other than removing the clutch cable to pull the motor and replacing the clutch cover gasket I've done nothing to it. I've read on some other threads about the plates setting up(hasen't been on the road since last year). I was wondering if the shift fork could have slipped out of it's proper place? I have not tried to do anything to fix the problem other than adjust the cable. Help...Moosehead is approaching and I have bugs that need to be addressed.Thanks.

Andy
 
I don't mess with Trannys. I like girls.

Sorry, I couldn't resist. I hope someone can help...
 
Could just be the clutch plates sticking. Try bump starting it in first gear then pull the clutch in and apply the brakes. Might need a couple of attempts to free it off. Best done with the motor well warmed up as the oil will be thinner and less sticky.
 
If it has been sitting for a long time the plates could be stuck together. Put it up on the centre stand, put it in neutral, does the rear wheel spin? No, ok, put it in first let the rear wheel spin, hold the clutch in and rev it up to 2-3000rpm, and apply the rear brake gradually a few times, that should separate them. Just check the cable again, it could be fraying at the ends and just stretching each time you squeeze the handle.
 
I would suspect the clutch arm on top of the clutch cover was not indexed properly when reassembled
 
My money is on the clutch plates being stuck since it sat so long. If the cable puller arm were in the wrong notch the lever pressure would be INSANELY stiff! Let us know who's right! :) Ray.
 
Pull the clutch cover off and pull out the fibers and steels. Soak the fibers in some clean oil and take some steel whool to the steels.
Plus it never hurts to have a looksy. You'll have to remove the brake lever and the foot peg.
 
Had that problem on the XS650 when I first got it. Just keep hammering away at it. Center stand, in gear and brakes is a good way to do it. If that doesn't work, try getting it started in first, pull the clutch in and accel/decel until it lets go. Might need a little back and forth action.

Of course, the best way would be to take it apart and do things right, but that's a lot of work.
 
rapidray said:
My money is on the clutch plates being stuck since it sat so long. If the cable puller arm were in the wrong notch the lever pressure would be INSANELY stiff! Let us know who's right! :) Ray.
Click to expand...

Ray, you can set these up the other way with the puller arm set too far clockwise and the clutch lever would feel insanely easy (the idiot typing this just did it!)
 
hampshirehog said:
Ray, you can set these up the other way with the puller arm set too far clockwise and the clutch lever would feel insanely easy (the idiot typing this just did it!)
Click to expand...
could you please explain?
thanks
i would have thought that the easiest operation on the clutch lever would be when the clutch puller arm travels equal distance both sides of perpendicular to the pulling cable :-k
 
Actually, it felt easier because you shortened the cable travel by doing that & it wasn't even moving the pressure plate. Ray.
 
OK, I pulled the fibers and steels, put the fibers in fresh oil overnight and cleaned the steels. They were clean and didn't seem to be stuck, reinstalled everything and still have the same problem. I can shift into first,but no further. While on the center stand, in 1st the wheel spins with the clutch lever in or out. cannot up shift. I checked the trans oil and it was rather low. I filled it until oil ran out the full hole, same thing, can't shift. The manual suggests the shifting forks could be bent or broken, I acctually didn't drive it when I bought it(only running on 3 cyl)The PO said he was riding it the day before without any problems. Other then running on 3 and sometimes 4 cyl. Almost decided to keep it because it was running so well. What should I do next??

Andy
 
That sounds reasonable. Trans problems are really my strong suit. Any ideas as to how to adjust the trans?

Andy
 
Then the question that begs to be asked, is the cable stretching? measure the length of travel of the cable on the clutch handle side and the clutch lever side, should be the same.

can you shift into any other gears with the engine off and on the center stand. you may have to rotate the rear tire a little bit to get it go into gear.

on the center stand, with the engine running and in 1st gear at say 3,000 rpm, pull up on the shift lever, the back off the throttle, did it go into 2nd? ( don't let it off the center stand please!)
 
The cable doesn't appear to be streching. Will not shift while running, will not shift while off, either. I removed the clutch arm to operate it manually, feels like there is nothing there, no restance at all. Also moving the shift lever manually, also feels like nothing there. Did manual operation with engin off, as well as running.
Should the pinion shaft spin freely? Or only turn a 1/4 turn or so? Mine only turns a 1/4 turn.

Andy
 
I had hoped it was something simple. Now you need to take the clutch hub off and have a looksy at the shifter forks.
 
ALB80-850 said:
The cable doesn't appear to be streching. Will not shift while running, will not shift while off, either. I removed the clutch arm to operate it manually, feels like there is nothing there, no restance at all. Also moving the shift lever manually, also feels like nothing there. Did manual operation with engin off, as well as running.
Should the pinion shaft spin freely? Or only turn a 1/4 turn or so? Mine only turns a 1/4 turn.

Andy
Click to expand...

You shifted into 1st according to your post so how can the shift lever feel like nothing is there?

I'm guessing you don't have the clutch cable, arm, and/or pull rod set right and aren't disengaging the clutch.
 
with the engine off, you should be able to shift through all gears back and forth (start from neutral, or if in 1st gear - rotate the back wheeel a little so it goes into the neutral easily
if you cant shift like this it's most likely a shifter mechanism prob

but is does also sound like your clutch isnt operating properly
make sure everything is back together as per the parts diagram and the centre nut is tight
it would pay to measure the plates and the springs to see if they are in spec

hopefully you have only one of these probs and not both!
 
Last edited:
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