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Message started by savageclay on 01/06/09 at 21:59:13

Title: Gear shifter help needed
Post by savageclay on 01/06/09 at 21:59:13

I have an 86 Savage. Some of you have seen the pics under bike pics. It's a sweet bobber.

The other day while riding the shifter dropped down about an inch or two and the bike would not shift gears. >:(

So i removed the plate where the shifting mechanism is. I removed the sping and looked around. Didn't see anything broken. Put it back together as described in the manual. While down there I move the shifter with my hand and it changes gears. I put it in neutral and fasten everything back together although I am unsure what caused it in the first place.

I then start up the bike. Go to put it in first and the shifter drops down again. Its like the teeth inside are slipping out of line or something. I really have no clue as this is the first time ever I have had to even open that cover.

Any help to a fix would be greatly appreciated!!!

Title: Re: Gear shifter help needed
Post by T Mack 1 on 01/07/09 at 03:39:50

Haven't heard of this one before (on a LS650 anyway)..... but you do have the first model year.....

On other bikes I would check the splines on the gear shifter shaft to make sure they aren't stripped and that the shifter linkage is clamped on to the shaft tightly. Maybe have someone shift while you watch real closely.

Beyond that, check to see if there is any elongation of the openings/holes that fthe shaft goes thru.

Title: Re: Gear shifter help needed
Post by prechermike on 01/07/09 at 04:19:28

I agree wit T Mack, I had a similar thing happen to my honda four trax. The splines on the aftmarket shifter had worn down. That was an easy fix.

Title: Re: Gear shifter help needed
Post by savageclay on 01/07/09 at 16:38:48

Thanks. It is definetly not the shifter. For some reason the teeth inside the shifter case are coming out of line. I guess I will have a dig in the manual and see what I can find.

Thanks!

Title: Re: Gear shifter help needed
Post by T Mack 1 on 01/07/09 at 19:36:51

Hmmmm.... this one may be a thinker....

Are you using the stock gasket material when you put it back together? My thought here (could be wrong) is too thick a material may leave some gap that so it can move.

Title: Re: Gear shifter help needed
Post by Breeze on 01/10/09 at 08:32:45

It seems that my wifes 87 has developed this same issue. In the next few weeks i'll be digging into the tranny to see what the problem seems to be. I've already done the external investigating and it is not an external problem.

Title: Re: Gear shifter help needed
Post by T Mack 1 on 01/10/09 at 09:56:49

SavageClay & Breeze,
When you figured out the issue, it would be very helpful for everyone else if you could take pictures & post something in the tech Ref section. Thanks in advance.

T. Mack

Edit: wonder if it's related only to the 4-spd models.... :-?

Title: Re: Gear shifter help needed
Post by Breeze on 01/11/09 at 05:16:01

Well, until S-Clay and now this one, i've not heard of it at all. My wifes bike has very low milage and she doesn't beat on it either. I dunno, at any rate, when the motor comes apart I will keep a journal of events and intensive pics. I hope to get to her bike around the end of the month. Once it's done or if I problems, i'll repost at the time with updates...

Title: Re: Gear shifter help needed
Post by savageclay on 01/11/09 at 14:48:43

Confirmed today that it is definetly not anything with the shifting mechanism behind the gear shift cover. It is starting to look like a transmission problem.

Title: Re: Gear shifter help needed
Post by savageclay on 01/11/09 at 14:50:17

Anyone know of a good step by step outline to repairing/replacing the transmission on an 86? 4 speed.

Title: Re: Gear shifter help needed
Post by Yonuh Adisi on 01/12/09 at 10:53:50

The tranny is integrated with the crank case so to replace it you will have to just go through it and replace all the gears.

Title: Re: Gear shifter help needed
Post by savageclay on 01/12/09 at 16:48:29

Ok I am fixed. Didnt have to get inside to the tranny at all. Turned out being the teeth on the shifting rod. I do still need a timing plug if anyone has one!

Title: Re: Gear shifter help needed
Post by justin_o_guy2 on 01/12/09 at 21:03:45

Turned out being the teeth on the shifting rod

but, but, but,, I thought that was the first thing you checked?

On other bikes I would check the splines on the gear shifter shaft to make sure they aren't stripped and that the shifter linkage is clamped on to the shaft tightly.

Thanks. It is definetly not the shifter.

DOOOOOH!

Yea, remember, I am the guy who desplodulated his battery with sparks from a grinder..

Super DOOOH!

Title: Re: Gear shifter help needed
Post by Breeze on 01/15/09 at 12:11:50

Ok, i've got the wifes thumper shifting again. Her's was not as easy as a stripped shaft. I ended up pulling the whole shift shaft assembly apart for a better inspection of the problem. First of all, be patient when going this route.

When I got the shift shaft exposed I found every thing to be what seemed to me to be loose. After playing with the shifter for a bit I relized that the shoulder bolt that holds the cam driven gear had backed it self out. After tightening it back up everything worked as it was meant to.After further inspection it turns out that there wasn't any loctite on the shoulder bolt. Be sure to reassemble with #271 Red loctite.

WHile I had everything apart I went ahead and disassembled everything to inspect it for worn parts. Everything seemed in order so, time to reassemble. A word of caution, when you do this be sure to take a cup of patience with you. The pawls and springs and pins are a pain in the uh huh to reasssemble. Deep breath then do it again. Thank goodness my wife has learned to be patient with me when working with such things.

Getting to everything wasn't as hateful as I antisapated anyou d if look where i'm pointing to, that is the shoulder bolt that had worked itself loose....I hope this helps others with a similar problem. I'll try to do a write up and procedure for this later.

http://i154.photobucket.com/albums/s264/TwoHyper/DSCF9883.jpg
http://i154.photobucket.com/albums/s264/TwoHyper/DSCF9891.jpg

Title: Re: Gear shifter help needed
Post by Max_Morley on 01/15/09 at 15:11:40

Where did you get the chromed crank hole cover? Thanks Max

Title: Re: Gear shifter help needed
Post by Breeze on 01/15/09 at 16:20:26

It was on the bike when we bought it. Wish i could be of more help .

Title: Re: Gear shifter help needed
Post by justin_o_guy2 on 01/15/09 at 18:04:34

Good goin' Breeze. Thanks.