Downshift Problems - won't go 3->2 or 2->1/N

[Flyin' Low]

I am having a recurring problem where after the bike is warmed up a bit, if I go to 3rd gear or higher, I can't downshift into second (and if I get to second, I can't get down to 1st or neutral). It's not just difficult - it won't go, even if I stand on it (and I know I shouldn't). The only thing that has worked is to rev it really high - 6-7000+ with the clutch pulled in and then I can usually click it down a notch. It's not completely consistent - sometimes it will be fine for a little while, then go back to not shifting.

Needless to say, this is an obnoxious problem. I just replaced the clutch cable (Suzuki OEM), hoping that would be an easy fix, since it was definitely still dragging when all the way squeezed in, but nothing seems to have changed. I noticed that with the cable disconnected, there is a lot of play (maybe 10 degrees) in the clutch actuator arm. Is that normal? And with the cable adjusted to have just a bit of slack, should I be able to squeeze the handle all the way to the grip?

Any help?! Is this a clutch problem or a transmission problem? Thanks.

Nick

[twiggy2cents]

you should be able to squeeze it to the grip
also it helps if the bike is moving
If your doing this at a stop it could cause that
There really shouldnt be any drag on the clutch parts when the lever is pulled
As far as setting the cable slack just screw the adjuster out until it is just snug then back a tiny bit

My actuator wobbles a little bit too if thats what your asking

[Flyin' Low]

This definitely happens when moving, not just at a stop.

[tkent02]

It has nothing to do with the clutch, these bike shift fine without the clutch.
Bent shift shaft, broken return spring, bent shift forks, open her up and see what's wrong.

[Killer2600]

Assuming the clutch isn't dragging when pulled in (as stated you should be able to pull the lever to the bar) shifting from 2 to N should be cake, if it's not then something mechanical is wrong.

[Flyin' Low]

Can these be checked out with the engine still in the frame?

[ryonker]

To look at your tranny parts, you will need to split the cases. This means Taking the engine out.

Rick

[tkent02]

Can these be checked out with the engine still in the frame?

You can check the shift shaft and the return spring by pulling the clutch cover and the clutch, can probably determine what is wrong from there.

If it's the shift forks or something internal that needs fixed you need to split the cases.

Start with the clutch cover. It's probably there.