easyrider470 Posted December 1, 2009 Report Share Posted December 1, 2009 ok so i have an 02 shee with minimal mods....been super reliable for years...strictly dune ridden. I am guilty of not always using the clutch when riding so I had this coming i suppose. Long story short the bike got stuck in a high gear...i think it was 3rd or 4th and the clutch level was moving but not down shifting the bike....i stopped and really kicked the shift lever pretty hard...i heard a grinding like when you are trying to find a gear in a stick shift car and then it slid into gear....wasn't first gear but it was 2nd. So i pulled the cover off today and there isn't anything obvious broken but the shift lever has a bunch of movement in and out....so the shifter fork isn't engaging the tabs on the shifter star.....i need to get the basket off to confirm what i am seeing though....what size socket do i need and does anyone know exactly what the issue is with this thing based off what I am describing??? Thanks a ton. Quote Link to comment Share on other sites More sharing options...
J-Madd Posted December 1, 2009 Report Share Posted December 1, 2009 You'll need a 32 mm socket to get the basket off. It's kinda hard to tell whats going in there until you get the basket out of the way. THe shift shaft could be bent. Does the shifter return to center after attempting to shift? Have you tried rocking the bike back in forth in gear while trying to shift (I'm sure you have, just thought I'd ask.) Don't remember for sure, but I think the side cover is what keeps the shift shaft from moving outward like you have described. Try turning the shift drum with some pliers to see if the drum or shift forks are the problem or if it is the shift shaft. Quote Link to comment Share on other sites More sharing options...
blowit Posted December 1, 2009 Report Share Posted December 1, 2009 http://www.mullengineering.com/sc/store.php/products/yamaha-banshee-yfz-rz-billet-shift-star-shaft-drum-transmission-race-drag-sand-shifting-hard-online Our longer engagement pins on our star correct most of these problems. Quote Link to comment Share on other sites More sharing options...
easyrider470 Posted December 2, 2009 Author Report Share Posted December 2, 2009 Ok, so i took the clutch off and the shifter is moving just fine up and down and it is returning to center when released. I did notice that it moves in and out enough to loose contact with the shift star tabs. Also, i noticed that with my wife moving the shifter, when the fork engages the star it DOES NOT MOVE THE STAR...even under heavy pressure and rocking the bike back and forth the transmission will not go into gear....seems like something is binding the star? Is that possible? Am I doing the wrong kind of check here...i never had any type of issue with putting the bike in gear before!!!! Let me know if I am on the wrong track or if i need to dig deeper. Quote Link to comment Share on other sites More sharing options...
easyrider470 Posted December 2, 2009 Author Report Share Posted December 2, 2009 Ok, so i took the clutch off and the shifter is moving just fine up and down and it is returning to center when released. I did notice that it moves in and out enough to loose contact with the shift star tabs. Also, i noticed that with my wife moving the shifter, when the fork engages the star it DOES NOT MOVE THE STAR...even under heavy pressure and rocking the bike back and forth the transmission will not go into gear....seems like something is binding the star? Is that possible? Am I doing the wrong kind of check here...i never had any type of issue with putting the bike in gear before!!!! Let me know if I am on the wrong track or if i need to dig deeper. Quote Link to comment Share on other sites More sharing options...
blowit Posted December 3, 2009 Report Share Posted December 3, 2009 Ok, so i took the clutch off and the shifter is moving just fine up and down and it is returning to center when released. I did notice that it moves in and out enough to loose contact with the shift star tabs. Also, i noticed that with my wife moving the shifter, when the fork engages the star it DOES NOT MOVE THE STAR...even under heavy pressure and rocking the bike back and forth the transmission will not go into gear....seems like something is binding the star? Is that possible? Am I doing the wrong kind of check here...i never had any type of issue with putting the bike in gear before!!!! Let me know if I am on the wrong track or if i need to dig deeper. If you cannot get the star to move in either direction, you have other issues. Make sure the detent arm on the side moves like it should. Also look over by the front sprocket and find the Al soft plug in the case that is about 3/8" in diam. If you have a pin working its way out of there, you have a problem. Sounds like something might have gave up in the trans but thought telling from here. Was there an event that started this situation? Start it without oil?? Quote Link to comment Share on other sites More sharing options...
easyrider470 Posted December 3, 2009 Author Report Share Posted December 3, 2009 The shifter moves just fine and it's almost like the little arm that grabs the star isn't moving far enough.....the arm moves up and down but doesn't move that star....Nothin unusual started this process just some good hard dune riding with my friends.....thing stuck in third gear and I had to mash the shifter to get it to neutral.....my buddy thinks it's a bent shift fork....the 2 3 shift fork....i'm going to pull the engine out tonight and split the cases to see if thee is anything else I can see.....like i said the shifter moves and rewturns to center just fine but it's not moving the star.....weird? Quote Link to comment Share on other sites More sharing options...
blowit Posted December 3, 2009 Report Share Posted December 3, 2009 The shifter moves just fine and it's almost like the little arm that grabs the star isn't moving far enough.....the arm moves up and down but doesn't move that star....Nothin unusual started this process just some good hard dune riding with my friends.....thing stuck in third gear and I had to mash the shifter to get it to neutral.....my buddy thinks it's a bent shift fork....the 2 3 shift fork....i'm going to pull the engine out tonight and split the cases to see if thee is anything else I can see.....like i said the shifter moves and rewturns to center just fine but it's not moving the star.....weird? That is an odd one. Make sure to have a pic or two of your problems. I would like to see what is causing your issue. B Quote Link to comment Share on other sites More sharing options...
camatv Posted December 3, 2009 Report Share Posted December 3, 2009 you need to have someone that knows what to look at with your trans gears out look at them after you get the cases split.. you should replace the shift shaft, guide pin, return spring ( if its worn at all) and all 3 shift forks. as long as the trans dogs are in good condition. also check the drum for guide pin problems. then STOP shifting it with out the clutch. if you dont want to use the clutch, buy an automatic! OR only try and shift it unloaded. very seldomly. that is your not on the gas at all. and your not coasting down a hill.. would you try and shift a toyota corolla with a manual without the clutch?? Quote Link to comment Share on other sites More sharing options...
easyrider470 Posted December 4, 2009 Author Report Share Posted December 4, 2009 well i have thought about building a lockout duner trans but i'm not going to do that till the motor gets ported...so that is a little while down the road. i am guilty of shifting without the clutch as well as clutching the bike a lot....i mean A LOT.....our dune group has a bunch of little kids that are learning to ride still and i always ride in the back....a lot of the time i end up getting close and bogg down and need to clutch the bike to get the RPM up....anyhow, i'm going o do the shift star mod so it'll shift better......looks like the all the shift forks are bent since it won't even go into gear... Quote Link to comment Share on other sites More sharing options...
J-Madd Posted December 4, 2009 Report Share Posted December 4, 2009 Did you every try to turn the shift drum with pliers? I don't know that a bent fork will cause all of the issues that you describe. Usually you just can't get into a particular gear, not failure to shift altogether, in my experience. Can you turn the transmission shaft, or is it locked up? Any metal in the oil when you drained it? Kinda hard to tell unless you have a magnetic plug. Quote Link to comment Share on other sites More sharing options...
rb0804 Posted December 6, 2009 Report Share Posted December 6, 2009 Did you every try to turn the shift drum with pliers? I don't know that a bent fork will cause all of the issues that you describe. Usually you just can't get into a particular gear, not failure to shift altogether, in my experience. Can you turn the transmission shaft, or is it locked up? Any metal in the oil when you drained it? Kinda hard to tell unless you have a magnetic plug. My guess is that he bent the shift fork shaft that the two shift forks ride on. This would explain why it was hard to get out of gear and finally into neutral. Those forks account for 1-4 with 5th and 6th engaged by the single fork on the opposite side. If the shaft is bent enough it will cause binding as the shift fork now cannot move like it should and it will be stuck in gear. You are going to have a hell of a time getting that thing out if it is bent that bad. would you try and shift a toyota corolla with a manual without the clutch?? Sure have,If you get the correct engine/ground speed, you just pull back on the gear selector and she slides right in, no problems. You should see the look on peoples faces! A car transmission is not like a motorcycle transmission and cannot be down shifted without the clutch. Shifting without the clutch is no big deal, the engine only needs a little bit of a interuption to get it to go into the next gear. You start slamming on the gear selector and downshifting going down hill and really abusing the thing, then you have a different story. Quote Link to comment Share on other sites More sharing options...
easyrider470 Posted December 22, 2009 Author Report Share Posted December 22, 2009 Sorry for the forever and a day on the update....here's the deal we tok it apart and found that the bearing on the gear the kick starter engages had disintegrated....so when the bearing came apart a piece actually got stuck in the cogs and locked up the piece that slides on the shaft to go from gear to gear. So, i replaced the bearing and put it all back together lastnight.....NOW THERE"S another problem!!!! The shift shaft that the clutch cable connects to is easily moved by hand and isn't doing anything.....clutch cable is limp.....oh and now the bike won't shift above FOURTH gear....so i'm pretty sure we missed something when we had the cases apart. So, recap.....i need to know why it won't go past fourth now....AND i need to know why the shift shaft where the clutch cable connects is dead...no resistance at all on the clutch cable.....did i mention how much i need to get this thing fixed because we are leaving for GLAMIS on SATURDAY morning.....oh yeah the huge trip of the year....gotta love it., Quote Link to comment Share on other sites More sharing options...
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