The bike fell over and the shifter lever broke, did not want to replace so I jury riged the shifter to the remaining shaft. Seems to work fine but can't get the bike to kick into gear. I adjusted the clutch, according to the manual, but still can't get it into neutral to start. Did something else happen when it went down? By the way the bike was only in first gear when the accident happened. Thanks for your help.
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Re: shifter lever broken...
It sounds like you bent the shift fork, or at least the shaft that penetrates the case and holds the shift lever on the outside. If you are certain you are moving the shaft and the bike won't come out of first then you will have to open up the case and see what is bent or broken inside.
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great question, how to fix.
verbs and all.
ok, a/t or m./t ( auto or stick:?)
toss coil and land (A/T)>
the shifter, is a lever.
the shifter connects to a cable
the cable connects to the transmission.
not sure what broke means, the lever fell off car?
or it wont shift. or is stuck , try to say what broken means.
but to fix it depends on which if the 3 parts are bad.
or if its park lock out feature, locking you in park.
you need to take the clutch cover off and inside you will find a small shaft going up to your clutch lever. If that lever is broken you will have to replace that shaft.If the clutch shaft checks out check your cable that could be broken. If it is then replace and adjust and you are good to go. Good luck on the bike
If the shifter is not returning to it's "center" position, the shifter pawl spring is probably broken in the transmission. With the engine off and the bike on the kickstand with the transmission in neutral, gently depress the shifter lever down until just before it shifts. Then, let go of the shifter and see if it springs back up. Do the same thing lifting the shifter towards second gear. Make sure there is no binding in the linkage. If you don't feel the spring pressure on the shifter, this is an indication that the return spring is broken. Harley had a problem with this on their 5-speed transmissions. Fixing the problem is a major job. You have to disassemble the entire primary drive and pull the trapdoor with both transmission shafts out of the transmission to get the shifter pawl shaft out. I strongly recommend the purchase of a service manual if you plan on doing this job yourself.
Usually when this happens, it's the shift lever on the shifter pawl shaft of the transmission has worn is loose. Start at the foot shifter and find the rod that is going back towards the rear of the bike. Follow the rod back until it connects to a lever. Wiggle this lever. Is the lever loose on the small shaft that it clamps onto? If so, this is your problem. Regrettably, this is fix is not a simple fix if it's done the correct way. It requires the replacement of the shifter pawl shaft and that requires a tear-down of the transmission.
To check the adjustment of the shifter pawl, first you need to have that lever tight. Here's the problem. You probably are going to find that the lever will not tighten. The splines on the shaft are worn out. This is bad. You must pull everything on the left side of the bike to get to the lever to replace it. If the spines are worn on the shaft, even a new lever is not going to fix the problem, the shaft must be replaced. This is a major job as the guts of the transmission have to come out. The shifter pawl shaft is the one of the first parts put into the transmission and one of the last to come out.
To check the adjustemtment of the shifter pawl, with the bike NOT running and the transmission in neutral, gently push down on the shfiter lever until the transmission tries to shift. Notice the distance. Now do in the other direction, pull up like you're going to second gear. Notice how far the shifter goes before it is stopped by the shifter fork trying to shift the transmission. There should be about the same travel up as three is down and the spring tension should be the same in both directions as well. To adjust the shifter pawl requires special tools as well.
It sounds like your shifter pawl is broken. It's trying to roll the shifter drum but it's not rolling it quite far enough for the drum to index to the next detent. It is rolling it far enough to put out the neutral indicator light. If this is the problem, a teardown of the transmission is required to repair this.
There is one other possibility. From the foot shift lever, follow the shifter rod back to the shift lever on the transmission. This is the shift lever that connects to the shifter pawl shaft. I"ve seen lots of them get worn to the point that they feel like they are going to fall off. When they get like that, they don't shift well. To repair this, you will have to pull the complete primary to get to it. If the splines on the shaft are worn badly enough, you're back to pulling down the transmission to replace the shifter pawl shaft.
There are two possibilities. The first is the most probable. From the foot shift lever, follow the shifter rod back to the shift lever on the transmission. The shift levers get worn and no longer shift the transmission like they should. You'll have to remove the outer and inner primary to get to the lever to replace it. If the splines on shifter pawl shaft are worn out, you'll have to pull the transmission down to replace the shifiter pawl shaft.
The other problem is that the shfiter pawl is broken and not rolling the shifter drum far enough for it to engage in the detent slots for the gears. To fix this is again, a teardown of the transmission.