Unexpected Neutral

[bikerphil]

I'm sure some of you must have this problem...

When taking off from a stop, you go about 10 feet and the bike pops into neutral. This would happen to me occasionally and always at the worst time. It can be very dangerous if you are crossing traffic, making a U-turn, etc. I recently figured out that the neutral light switch was causing this problem. Apparently the tip of the switch contacting the shift drum eccentric gets worn and sloppy. This will prevent the drum from fully seating in it's proper location when shifting into first gear when coming to a stop. Here's how I found this out. I had oil getting on my left boot coming from the neutral switch, we all know these are prone to leak. I replaced the switch with a short 10mm 1.25 pitch bolt and a crush washer to stop the leak. I immediately noticed that the shift to first gear felt more solid and I have done plenty of stop and go riding since the repair and not any popping out of first to neutral. I have never read of this topic coming up on this site before so I figured I would pass it along and I hope it helps sombody.

[scoot]

Well, you have described exactly what I'm going thru now. I figured I need to do the second gear fix to first gear this winter. Downshifting into first coming to a stop, odd are pretty good that it will pop back out of first into neutral as I fully stop. Or it will pop out of first when I take off right mid intersection. Then I need to tap- tap the shifter to get it back into first or tap up to second while the rpm's are low, then chug away as the power band picks up. Not very smooth, kind of sucks. I'm gonna try that bolt swap- out and see if there's a change. Thanks for the heads up.

scoot

[patk12345]

Happened to me not more than 15 minutes ago. Besides your body lurching forward as the bike suddenly stops, and praying the car behind doesn't hit you, you also get to enjoy the feeling of everyone at the intersection staring at you, and thinking you're a total ass because apparently you just stopped your bike to rev up your engine. Definitely, going to investigate this.

[bikerphil]

Yep, just make sure the bolt is shorter than the neutral switch itself. I used a shoulder bolt with a 14MM hex, the shoulder provides a good surface for the crush washer to seal to. When you take the switch out you will probably find the spring loaded brass contact is chewed up. If you really must have your neutral light back, a new switch is about $20. If this fix doesn't help you, then your gears probably do need resurfacing. Good luck!

[crazy steve]

Good tip Phil! I'll file that one in the ol' memory banks...

[SFerinTEXAS]

Recently did the 1st gear fix on the XJ, (+2nd touch up) and pulled the shift drum. Got the WTF is this when the drum detente spring and tip came out. Fun getting it back up above the drum when reinstalling. Just can not see the neutral switch having any kind of over riding effect on that detente spring. Got to be more to this problem than seems . Maybe the shift pawl setup needs a look. The switch has no control on the drum

[bikerphil]

Recently did the 1st gear fix on the XJ, (+2nd touch up) and pulled the shift drum. Got the WTF is this when the drum detente spring and tip came out. Fun getting it back up above the drum when reinstalling. Just can not see the neutral switch having any kind of over riding effect on that detente spring. Got to be more to this problem than seems . Maybe the shift pawl setup needs a look. The switch has no control on the drum

I wouldn't think it would over ride the detent ball either. The switch end had sharp grooves ground into it like it was misaligned with the stopper plate and riding on the sharp edge instead of in the center. It's possible the stopper plate might have some side play in it to cause this. My theory is that it would somehow keep the drum from going far enough to the detent and locking in position. Believe me, I have tried every necessary alignment and adjustment of the shifter pawl with no avail. Just removing that switch has cured my shifting problem, YMMV.

[motoman]

Looks to be just be an added 'glitch' the older these scoots get......

[SFerinTEXAS]

Next time I pull that switch Will give it a big Eye Ball Never leave anything to chance.

[DGXSER]

interesting, not something I have experienced yet, but may. I'll take a look at that switch to maybe stop this before it happens.

[bikerphil]

I replaced the switch with a short 8mm 1.25 pitch bolt

This is incorrect, it should be 10mm x 1.25 pitch.

[TopCatGr58]

Hey Phil,

Great info, will need to remember to put it in the Repair or MISC forums tech tip. I editted your original post to the 10mm you stated.

T.C.