While riding, my bike doesn't go into 4th gear. It doesn't click, grind, etc. It's like the gear doesn't even exist. When I split the case all the gears were in great condition and it appeared to shift easily. Any ideas?

Have you inspected the gears that are actually in the transmission? In the picture you're just looking at the drive gears on the clutch, crank, etc.

Yeah, all the gears were in great shape. I took this pic right after we split the case just to show what condition it was in. I really don't want to pull the engine apart again...

Check the shift drum detant pin. It's on the crankcase on the back.

I checked the pin. It appears to be in good shape. Should I buy a new spring?

Check the end for burrs and polish the tip. I'd try to stretch the spring just a little. My guess is a burr on the shift drum or pin.

I see. I agree with sprintdoc... since you're not even getting any grinding, I'd concentrate more on the linkage than the gears themselves. Did the shifter forks look OK? (not bent or damaged) Will it shift into 4th when it's not running? What do the shifter pawls do? Does it feel like the shifter is stopping short (getting hung up) when you're shifting, or does it have the normal amount of travel with no effect?

This post was last modified: 04-16-2010 05:45 PM by squirt.

Doc, I'll give that a try.

Squirt, Everything looked fine inside. When going through the gears (not running) it doesn't always seem to catch the next gear. Sometimes drops back into neutral. So it's hard to tell what gear it's in. After I stretch the spring I'll see if gets any better. Would you recommend a newer stronger spring?

Thanks for the advice!

I'd just stretch it a little bit and see if that changes anything. Just a little bit. Sounds to me like your clutch may not be adjusted right and dragging a bit. That will make it shift like you described.

Your shifter pawl has two spring loaded pins on it. Sometimes things get corroded up and the springs will not push the pins back up, ultametly not letting the pawl to move the drum. Check to see if this is the cause.
Tom