Hard shifting into second gear

[Mekanix]

It was okay but still caused some hard shifting as the bike died at a stop with the clutch pulled in and it would lurch on me in gear. Plus, I would have to add gas to get it into gear or let it drop to 3500

Well that's going to lead you in another direction.

Clutch.

or clutch basket has grooves the plates are sticking in.

Possible warped or bent plate.

Possible missing washer/ spacer between the clutch pack and basket.

I took it off and turned the whole assembly about two teeth so the mounting screw lined up with the N(Neutral) on the sprocket cover

Could it be that it feels better because the shift leaver is in a position where you have more mechanical advantage with your foot at this new angle ?

I'm thinking maybe it took more effort to move the leaver where it was but now its easier to move since you have more leverage or it feels more natural.


How does it behave without the engine running ?
Can you shift through all the gears without any feeling of binding ?
How does the shift lever move with and with out the cover on. Notice any binding with it on but not with it off ?


Here's something I would try.

With it idling and on the center stand, shift to first and release the clutch and then shift to second and on up and down with the clutch or without.

If its the clutch that is the problem, you will not notice anything while shifting up and down.
It would feel normal.

If its the shift mechanism, (forks, drum etc...) you will feel binding when trying to shift when there is no load on the back tire.

Hope this helps.

[cowboyup3371]

Well that's going to lead you in another direction.

Clutch.

or clutch basket has grooves the plates are sticking in.

Possible warped or bent plate.

Possible missing washer/ spacer between the clutch pack and basket.

Very possible but I doubt it only because I just got done inspecting everything before taking it to Denver two weeks ago. Plates all measured within tolerances and the basket didn't have any grooves on the inside. Now there was some scratching on the outside of the basket though. However, the plates are getting close enough to say I'll replace them next winter for the heck of it.

Could it be that it feels better because the shift leaver is in a position where you have more mechanical advantage with your foot at this new angle ?

I'm thinking maybe it took more effort to move the leaver where it was but now its easier to move since you have more leverage or it feels more natural.

Foot position and angle haven't changed that I noticed either during yesterday's ride into work and back (44 miles round trip) or the short jaunt up and down my dirt road today.

How does it behave without the engine running ?
Can you shift through all the gears without any feeling of binding ?
How does the shift lever move with and with out the cover on. Notice any binding with it on but not with it off ?


Here's something I would try.

With it idling and on the center stand, shift to first and release the clutch and then shift to second and on up and down with the clutch or without.

If its the clutch that is the problem, you will not notice anything while shifting up and down.
It would feel normal.

If its the shift mechanism, (forks, drum etc...) you will feel binding when trying to shift when there is no load on the back tire.

Hope this helps.

Haven't checked this part really but something to look into; I'll try to check it out in the next couple of weeks before Brown County. Want to get some riding down first and the remainder of the gears feel great while the bike's running. I only had the problem going up between first and second. It's kind of the reason I think Ed's advice really took hold of me after seeing the before picture vs what I put back on difference.

Thank you for the advice Mekanix.

[cowboyup3371]

So it is finally fixed for sure it looks like

I finally have it done right. Yep the bike shifts correctly now and I'm not dying at stops from the clutch not disengaging while pulled in. Here's what started from yesterday when I posted that I thought I finally had it close to being fixed.

So yesterday, I grabbed the Clymer's manual and read through it while I adjusted everything. I loosened up the handlebar locknut as well as the little screw and nut at the sprocket cover. Then, I also loosened (unthreaded) the cable as it went into the sprocket cover a couple of turns. Then, I measured the free play at the lever to what I thought was the 2-4mm per the book (1/16 to 1/8"). When I first test drove it it felt good.

As I took off this morning and got to the gas station, I couldn't pull the clutch in again without the bike stalling. Okay, no big deal as I'm at a stop. But when I went to take off again, the bike stalled if I tried to shift from neutral to first gear. The only way I could get the bike to stay running was to start it in first while the bike lurched forward even with the clutch handle fully depressed. Definitely not very safe and I wasn't happy with it.

So I get to the base and before going inside I try to adjust the cable again. Only this time all I did was to loosen the locknut at the lever (I noticed what I think was a lot of play in the lever) and then loosened the nut where the cable goes into the sprocket cover. After doing that a couple of more turns from where I had it yesterday, I tightened up the locknut at the lever and tested it. First thing, I was able to shift into first gear without the bike lurching forward as the lever was pulled in. I then found neutral very easy from first while the bike was running. And finally found second from first without any problems and very smoothly.

Finally, on the way home tonight while fighting 25+ mph winds from the south (I'm driving east), I noticed that my shifts into second were back to being completely smooth and stopping at stop signs occurred in first gear without killing the engine again.

I'm definitely a happy camper. I appreciate everything you all have done. Hopefully I don't have any more issues.

[Steve]

I guess that means we'll see you at Brown County after all?

.

[cowboyup3371]

I hope so Steve since now I'm thinking of changing out the front springs and steering head bearings and not sure I can get it done by BC. I hate hitting the ground so hard after every bump