Gen II - Downshifting issue

[Mike Aldea]

I've noticed an issue with downshifting on my 2006 since I've bought it in April. Many times my motor refuses to downshift more than one gear without letting out the clutch completely between gears. The problem does no occur 100% of the time but it does seem to occur about 80% of the time.

Sometimes repeated steps on the shift lever will finally get it to select the next lower gear. Other times it just won't go any lower until I let the clutch out or come to a complete stop. One time I actually found myself in neutral between 3rd & fourth gear!

I've tried blipping the throttle while the clutch is in between strokes of the shift lever and that does not seem to have any consistent effect on the problem.

I've never experienced this problem before in over 35 years of riding Kawasaki and Suzuki inline-4 motors. I'd always heard how good Yamaha transmissions are so I'm very surprised by this behavior. Do I have a unique, a.k.a. expensive, problem?

 

[road runner]

Maybe your shift lever pivot shaft is sticking. Go out and shift the bike and make sure the shift lever returns back. The shift lever always want to be , say in the middle. If you shift up and release the lever should spring back down. Same with shifting down it should spring back up on its own. If not then remove the lever, clean and grease. That should do it.

 

[rbentnail]

Actually, to me the method you describe as letting the clutch lever out between gears (albeit not all the way but at least a little) seems quite normal to me and is a habit I developed through necessity. My '07 requires it as did an '04 Kawi 1500 before that and an '03 Honda Shadow Sabre before that and an '03 Kawi 800 before that and .....

But check this- I also found that this bike will easily upshift without clutch usage but can be a real bear to downshift without it. Start simple: replace the clutch fluid. But on my bike, the first 100 miles or so of city driving with lots clutch use requires special care. It's like the clutch won't disengage to allow easy and smooth downshifting. Then the problem magically goes away and all is right in the world again. Happens every year without fail when I replace the fluid.

 

[08FJR4ME]

A couple of other sugestions. Try adjusting 1,2,3,4 and 5 on the knob. You could be improperly adjusted. Next is the linkage on the shift peddle. You should make sure it is well lubed. After all sugestions it is going to cost you $$$$$.

Good luck,

Dave

 

[Mike Aldea]

A couple of other sugestions. Try adjusting 1,2,3,4 and 5 on the knob. You could be improperly adjusted. Next is the linkage on the shift peddle. You should make sure it is well lubed. After all sugestions it is going to cost you $$$$$.
Good luck,

Dave

What knob are you referring to?

 

[dcarver]

The knob on the clutch lever, Mike.

BTW, bleeding my 06 clutch, with just over 1 year of service since last flush, made ALL the difference in the world.

Hopefully the same for you.

The other alternative, shift forks, are expensive.

 

[Bustanut joker]

A couple of other sugestions. Try adjusting 1,2,3,4 and 5 on the knob. You could be improperly adjusted. Next is the linkage on the shift peddle. You should make sure it is well lubed. After all sugestions it is going to cost you $$$$$.
Good luck,

Dave

What knob are you referring to?

The little one.. Between Carvers ears!

jeebus dude, the inconspicuous knob on the lever

 

[wfooshee]

The knob on the lever doesn't really affect the clutch operation, but simply positions the lever relative to the handlebar, for big hand vs small hands. If it does affect your clutch, i.e. clutch doesn't disengage unless you're on '5' then you have other issues.

The OP's issue sounds like sticking shifter, not a clutch problem. If the lever doesn't return to center after a shift, then the ratch can't catch for the next downshift. Clutching in between shifts instead of just kicking down 3 times in a row jars the bike enough to spring the lever free to the center.

The shifter and the brake pedal both need periodic cleaning, as they grunge up and stopp moving freely.

 

[Fred W]

Maybe your shift lever pivot shaft is sticking. Go out and shift the bike and make sure the shift lever returns back. The shift lever always want to be , say in the middle. If you shift up and release the lever should spring back down. Same with shifting down it should spring back up on its own. If not then remove the lever, clean and grease. That should do it.

This is good advice. You'll find that there is a spring washer (intentionally made curved) behind the shift lever. It is there to eliminate lateral slop in the shift lever assembly. It also means that if you get road spooge in there the shift lever can easily get sticky. It is a small maintenance that is best done on regular intervals.

But check this- I also found that this bike will easily upshift without clutch usage but can be a real bear to downshift without it.

If you value your riding time (vs. wrenching time) I would not get into the habit of doing clutch-less downshifts. Sure, up shifting that way is OK as long as you let off the throttle while shifting, but there is no way to adequately unload the gear dogs when downshifting. Eventually you'll bend the shift fork and that is not a fun repair (means removing the engine and splitting the cases.) It isn't all the hard to pull in the clutch lever, IMO.

The knob on the lever doesn't really affect the clutch operation, but simply positions the lever relative to the handlebar, for big hand vs small hands. If it does affect your clutch, i.e. clutch doesn't disengage unless you're on '5' then you have other issues.

I disagree with the second sentence. Yes, the adjusters are provided for ergonomics (to adjust for dainty hands), but many folks with second gen bikes have reported that they get some clutch drag if they adjust the levers in towards the bars too far.

However, I don't think this symptom is related to clutch drag or the difficulty wouldn't be just down shifting more than one gear. It would be difficult to get the bike in gear from neutral. I would guess it is either a sticky lever, or maybe the lever is adjusted too high, such that the OPs foot/boot is still bearing on it keeping it from releasing fully?