3rd-4th gear crunch

[sthomag]

Shifting between third and fourth gear on my bike always feels like the dogs are rounded off: Crunch! Fourth to fifth, on the other hand, is smooth as silk.

Is this a common problem? I'm assuming that, to fix it, the cases need to be split so as to get at the mainshaft. Are there any other possibilities?

[DGXSER]

Do the gears mesh together and stay after the crunch? Does it just not shift and you have to hit fifth?

Have you adjusted your clutch cable at both ends, engine side first, then adjust the slack at the lever?

These bikes do NEED avery FIRM shift. I have to admit that occasionally I slack off and find a "false neutral" between third and fourth usually. Then you have to increase RPM , pull clutch and hit the shifter liek you mean it. Really, you have to pull all the way up, every time. Stop just a little short and you will miss the gear.

[sthomag]

It stays in fourth just fine. It's just that the "crunch" is so obvious.

[DGXSER]

If it stays in gear, it is probably not the dogs being rounded off. The symptom of the rounded dogs is that it will go into gear, but keep popping out, and back in. Like an M-60 cycling the bolt.

Might want to check the shift pawls are in line. Or that the plate on th end of the shift drum is not bent. Just a couple thoughts.

[sthomag]

I recently replaced the clutch fiber plates, although I probably didn't have to. There wasn't a whole lot of wear on the old plates, and the metal plates looked brand new.

I adjusted the clutch only at the lever. Am I missing something?

[DGXSER]

Yes, The clutch adjustment is a two part process. First, loosen the adjuster at the lever so there is plenty of slack in it.

Now, remove the two phillips screws and the cover plate on the clutch cover. Under there is the first adjustment point. In the middle you will see a phillips screw ned on the adjustment rod, with a lock nut on it. loosen the lock nut, then loosen the screw out, now tighten the screw until it JUST seats against the clutch. Now loosen it about 1/4 turn and hold it there while you tighten the lock nut.

Now go back to the lever end and adjust your slack so you have about 1/8" of slack.

[jetmechmarty]

It is easy to get neutral between 3rd & 4th. That is also the shift where you don't want to get sloppy. A quick firm pull and it should be fine. Shift like you mean it!