While we are on the subject of gears... Strange shifting

[Orange4]

Got it back together. Still doing it a bit but only when I shift down while crawling or not moving.

So I guess it needs either a stronger spring or adjusting.

[Orange4]

It was still acting up so I read the instructions you gave me. "Likely shift pawl out of adjustment....remove shifter and cover after engaging to SECOND gear. Alignment marks align....if not, adjusting is done at the cam eccentric at shift shaft, lock but and adjustment screw. " the alignment was out after shifting to second so I adjusted at the shift shaft eccentric.

I also found this :

Tab lifted. Should I crimp it back down?

[motoman]

It was still acting up so I read the instructions you gave me. "Likely shift pawl out of adjustment....remove shifter and cover after engaging to SECOND gear. Alignment marks align....if not, adjusting is done at the cam eccentric at shift shaft, lock but and adjustment screw. " the alignment was out after shifting to second so I adjusted at the shift shaft eccentric.

I also found this :

Tab lifted. Should I crimp it back down?

....it will break.....100% of the time......and when that pin falls out, you'll be left in whatever gear it's in at that time. Gonna have to replace that 'washer'. Used to be still available from Yamaha, not sure if it still is.

Either way, your 'down' till that's replaced. Members here may have an 'extra' there willin' to part with also.

[DiverRay]

You COULD use silver solder to try and keep the washer over the pin. You would need to CLEAN AND DEGREASE the washer first, then bend back S.L.O.W.L.Y and put a glob of silver solder on the keep it from breaking. Welding may also work, but it will still need to be CLEAN! That is the hard part!!

[Orange4]

Thanks guys. I can weld it with my TIG. It's been like that since I got it unless it happened from being out of alignment. Could that have been part of my problem? The shifter was sticking down after downshifting and I had to pry it back up with my toe while riding. Then it usually ended up in second.

[mack]

If he

is in second gear for this photo then the the shift drum is out of alignment as well.

[mack]

Alignment

I may have mis-spoke. Those alignment marks on the pawl and drum should match up in second gear. I can't tell from the photo but in second, the drum mark should point at the bolt hole that is at the 10 o clock position and the mark on the pawl should be dead on in line. I wonder if the little spring at the swivel between the pawl and the fork is broken/ missing or weak.

[Orange4]

When you see the marks straight on they are dead aligned now. It's the angle of the pic that's making it look out. It was almost .1" out before I adjusted it.

For some reason I forgot to mention that it was often really stubborn about shifting down into first even when the shift lever didn't get stuck. I'm optimistic now that it will be better as it was well out of whack.

I bent back the tab but it was rather crunchy so it will probably let go at the first small shock. I'll have to TIG it as you suggested. That that's one brittle washer. A little acetone will clean that up good. Does that pin move or is that just a retaining tab?

[motoman]

When you see the marks straight on they are dead aligned now. It's the angle of the pic that's making it look out. It was almost .1" out before I adjusted it.

For some reason I forgot to mention that it was often really stubborn about shifting down into first even when the shift lever didn't get stuck. I'm optimistic now that it will be better as it was well out of whack.

I bent back the tab but it was rather crunchy so it will probably let go at the first small shock. I'll have to TIG it as you suggested. That that's one brittle washer. A little acetone will clean that up good. Does that pin move or is that just a retaining tab?

.....post #18....tab holds it in.

[BA80]

it was often really stubborn about shifting down into first even when the shift lever didn't get stuck.

If the lever is sticking/not returning properly the return spring is probably weak or even broken.

[Orange4]

I don't think that's it. It's not broken for sure. It only gets stuck occasionally and when it does there's no way a spring could overcome the friction. It takes quite a bit of force to unstick it. We shall see though. I could be wrong. It's happened before. I'm fixing one thing at a time so I know what did the trick.

[Orange4]

I'm wondering how it got bent in the first place

[motoman]

I'm wondering how it got bent in the first place

Jumping in and out of gear.......second or first.

[Radioguylogs]

If the lever is sticking/not returning properly the return spring is probably weak or even broken.

Happened to me, but it didn't take much force to get it unstuck. It was most noticeable in upshifts >3rd.

[Orange4]

This will have to do for now. That's a 308L 1/16" filler rod welded to the washer. I also did a bunch of little jobs that have been nagging at me like properly mounting the spaghetti pipes. Next job is to replace a few exhaust studs that have been bodged by the PO.