i now think i bent the shift washer this time

[geniusloerts]

Went riding yesterday i was on my brothers XS and my friend was on mine. well we get to a stop sign and he says that he can shift. so i thought it was the pesky 1st gear acting up like it does. but it turned out that he couldnt shift down into 4th.....so i got on it and managed to get it to shift to 4th and told him that we would just limp it back home......well on the way home i was able to get into 3rd, 4th and 5th no problems but into 2nd and 1st......forget about it!(NY mafia)

so my theory as of right now is that the washer that holds the shift pins in place bent and those 2 pins fell........i will be opening it up again after work to check it out..

any other thoughts?

[DVigue]

I actually used a "fender washer", used a dremil to cut it to the general proper shape, used pliers to bend up and make the 2 tabs. Used the old one to mark and drilled the extra holes in the middle. Make sure you pick a washer with the correct middle hole though. Looks ugly as hell but appears to be holding it all in place and has a cover over the top of it. Was told by Yammy that it would be 2-3 weeks before the proper replacement arrived in shop.

[TopCatGr58]

Hey Genius,

Aside from the shift drum pins falling out, the return spring failing is another cause for difficulty in DOWN SHIFTING! When it's weak, it doesn't lift the shift lever far enough back up to allow the shift pawl to grab the next pin on the drum, no further downshifting...until you "GENTLY" lift up on the shift lever enough to allow it to grab the next pin without shifting back UP into the next gear, THEN you can shift down into the next lower gear, and then repeat the process to keep DownShifting!
T.C.

[geniusloerts]

errrrg........2 times

ok...so it wasent the shift pins this time.......

about 2 weeks ago the c-clip poped off the shift shaft that runs across and runs the gear that connects the clutch basket with the oil pump gear.....

well it poped off again!!!!! i dont belive it!! after further examination the grove in the shaft where the clip rests is warn a bit so it allowed the clip to slip off!!!! so i fixed the grove by using a file to deepen it a bit and a hair smaller clip and whoa laaa!!! a temperary fix.....i am going to pull it apart again but everything and do the gear fix and change out the shaft.