keep getting stuck between gears....

[lastlegwarrior]

I've got a 2000 shee, i had to split the cases because it got stuck between 3rd and 4th gears while i was out riding. I've checked the shift shaft it's straight, adjusted the little hooks or whatever grabs the little shift star to their proper adjustment, checked the shift forks they look fine, and yet it still seems to get stuck between the gears. The wierd thing is, it may shift through all six gears fine but when i shift back through them it gets stuck again. It does this upshifting and downshifting, you just never know. By looking at the gears in the tranny, what is happening is whenever i shift and it gets hung up the gear that are supposed to slide over are mating properly with the gear it is supposed to. Also sometimes when the gears get stuck if i roll the gears by hand it all the sudden pops back into place. what gives?? Any info would be greatly appreciated.

[MotulMonsta]

Your shifter cam may have grooves in it, your forks may be bent or worn. The shift star is connected to your tranny cam and the forks ride in the grooves..as you change gears you rotate the cam which moves the forks, when the forks move they engage/ disengage cirtain gears..on the gears themselves are dogs and if they are worn, they cause the gears to stick..if the gears stick, the forks can get bent..if the forks are bent, they wear out the cam if the cam is worn, well now you pretty much have a worn out tranny.

[lastlegwarrior]

just went outside and checked it, shifts fine once the gears are removed. shift forks are straight, cam is looks good no additional grooves or rub areas. It's like the dogs (or the teeth that hook the gears together) aren't lined up right because as soon as you rotate them to the right spot everything clicks. got anymore ideas.

[lastlegwarrior]

bump, anyone got any ideas?

[MotulMonsta]

The dogs on the back of the gears should be square. Do you have a repair manual? They give the tolerances allowed for wear in the tranny. I assume you've already tried to adjust your shift lever where it engages the shift star? There's a little screw that will change the throw of the lever. There is also a spring. If that screw is worn or the spring is weak, you won't be able to shift right. Also pay real close attention to how you assembled the tranny..perhaps you've installed a part incorrectly. The shifter forks slide not only on the cam, but on rails too..make shure those arn't bent or worn.

[JKJK]

the shaft that the gears ride on could be worn,if it's apart it's only a couple of snap rings,to slide the gears off+check it out.

[lastlegwarrior]

yes i have a repair manual, clymers, i think. motulmonsta thanks for the help, right now i'm in the process of tearing down the two gear holding shafts (i don't know what the actual name is) and giving them a thorough cleaning. I don't have a run-out meter or gauge to check the shafts, they look good, i might have a local shop check the run-out. I also have one question how can you tell if the shift forks are worn, i've never seen a new one, so i'm kinda in the dark here. On my shift forks you can tell something has been rolling or wearing in the grooves, it doesn't look bad the rub area is smooth. (should they even have rub areas? I also have checked all the gears and they look good, no missing teeth or chips. The dog teeth also look good, all of them have that square shape you were talking about. Keep the info coming, once again thanks.

[lastlegwarrior]

JKJK, the shaft appears to be fine, all the edges are nice and square and sharp, the shaft also appears to be very smooth, anything else i should check for. thanks for the info.

[MotulMonsta]

Ok, The forks are numbered and need to be installed right. If they are bent and worn, they should be replaced. Pretty much, if it doesn't move smooth, it should be replaced..the forks, cam..check the gears themselves by moving them, and engaging the diffrent gears with them just sitting in the cases..everything should be smooth. Maybe you have a bad bearing in there or something is bent..maybe the forks are installed wrong..they all look the same, but they are all diffrent..pay attention to that..notice the numbers on them. My tranny is from 1987..My shit is crazy worn but it still works..I got issues going from 2nd to third sometimes..but tranny's arn't cheap. So I hope your problem won't cost you much money.

[1998_Banshee_Racer]

I just got my shee put back together and I had this same problem and had to take it back apart.All that was wrong with mine was that bar that goes under the shift star with the roller on it had come loose and wasnt pushing up on the shift star like it should so it was just kinda letting the star set in between the things that shift it.Then I tightened it ,it shifted great and smoother than ever make sure that bar w\the roller is touching the shift star and not behind it because then it wont work at all if it gets behind the star.

 

Hopefully this will help you.