Serious Gearbox problem :(

[yorkie_chris]

Right then time to inspect the external shift mech.

What is it doing in second which is different to the rest of the gears, possibly one of the dowels is bent and it's needing pushing down before it's dropping into the notch properly.

Originally Posted by yorkie_chris

Right then time to inspect the external shift mech.

What is it doing in second which is different to the rest of the gears, possibly one of the dowels is bent and it's needing pushing down before it's dropping into the notch properly.

hi m8

basically it seems it doesn't "reset" itself, so ive made a vid for you to see (sorry about quality)

it shows me selecting 1st then 2nd and you will notice at 57,56 seconds to go i lightly pull on the lever and it "resets" again, then onto 3rd,4,5,6

http://s35.photobucket.com/albums/d1...t=MOV00266.flv

sorry if i explain crudly not a true expert

thanks allot for your help

phil

[yorkie_chris]

You don't need to be so rough with it for a start! If it doesn't want to select a gear when it's trying to move stuff then just slowly move the wheel while maintaining pressure on the lever, it'll drop in smooth as owt then.

Anyway, not resetting in second seems to indicate the problem is external, which is good news.

Need to go and look at an engine... back in a bit!

[yorkie_chris]

I'm thinking the shift detent cam, have a gander at it and see if any of the pins look bent or chipped.

right just had a look, and ive found it

cam shift plate is broken, its basically got a piece taken out of it at the top. doesn't look like a bottle opener now lol

so that seems to be the problem, would o noticed it earlier but i thought that was how it was

now where can i get one of them from?? and do i need to take the clutch assembly completely off, if so i will do that while finding a cam shaft plate

thanks again for your help yorkie

[yorkie_chris]

I've got one. make me an offer

do you mind if i can have a picture of it

mainly cause ive just seen the parts chart http://alpha-sports.com/spst/2006%20SV650S/32.gif

figure 19

and that is split in the middle to, is this right? as thats how mine looks

[yorkie_chris]

The one I'm looking at is complete like a bottle opener, pics to follow.

Originally Posted by yorkie_chris

The one I'm looking at is complete like a bottle opener, pics to follow.

hmmm this is confusing

i looked on that abba site on the 2003 and 2004, they look like a bottle opener. but 05> they have a split in

[yorkie_chris]

Not impossible that they'd change over the years, but thinking about it that plate would affect all gears. I still reckon it's the shift star/detent cam which is at fault.