Join Date: Jun 2012
Location: A couple places
I know this an older thread, but I was looking for the answer to a balky shifter. The solutions here did not help. Soooo..... it's a training bike with 2900 miles. Don't remember the year, but it's white pearl with the flames on it, so it's a later model. I figured if I can't use it, may as well dive in to see what the issue is. I can sell it, junk it, etc. I have one on the second lift that is being parted out and am using it to compare.
Drained the oil, took the cover off. Cover popped right off and clutch lock nut was not properly staked. Evidence that someone had been here before. Checked the star wheel that selects gear - everything looked fine. Bike would hang between gears when not running and not shift at all when warm. Kept comparing. Took clutch off. Still good. Removed star wheel and shifter shaft. Turned shift drum by hand. Would occasionally hang, but I figure most bikes will when they aren't running. Turned mainshaft (the one the cltuch is on). Bike will drop into gear - sometimes requiring a jiggle or more turn of mainshaft. Looked up in the case where you can see gears and shifting going on. Everything looked okay - could see things moving and they felt pretty smooth.
Studied manual and other bike. Checked to see if there was play in mainshaft - AH HA! Seemed to be a LOT of end play. Compared with other bike, which does not have very much end play. So put it all back together short of clutch and messed with shifting a lot. Found that when the bike was hanging between gears was when the mainshaft was moving to the outer limit of the end play. And looking at the star wheel, can see that it is hanging up between gears.
Played with it some more. I feel confident that the end play is the cause of the sticking shifter on this bike. When the shaft moves OUT, the shifter hangs.
The oil had been changed, the cable was properly adjusted. Sooo.... this one will probably get a motor swap - splitting the cases is beyond the scope of our repairs here. And I got extra motors...
SO if nothing else helps, you may have to look deeper into the problem. Be sure to check that end play - could be the culprit.
I figured this is as good a place as any to post this. When you google "rebel hard shifting" this is the first link that comes up.