Stuck in 2nd & 3rd gear.

[CRMH Eagle]

One of the MANY things I accomplished on the bike the past weeks is a clutch bleed. During this time I had the foot shifter off to lube the pivot points. This morning I take the 1st ride since having the bike disassembled the past 5 weeks.

The clutch lever moved easily and so did the foot shifter. After taking the bike from 1st gear to 3rd, it became difficult to go into 4th. After a few miles I turned around for home. Near home it would go into 2nd or 3rd. I'd engage the clutch lever and keep pressing down or up on the shifter and no change.

So I did another bleed 30 mins ago it still only goes into 2 or 3. The foot lever appears to be installed correctly. Clutch lever operates normally.

Do I need to flush a LOT of fluid down the pipes since there still may be air in the system?

 

[madmike2]

It's not the clutch.

Double check all the linkage on the shifter.

 

[FJRBluesman]

It's not the clutch.
Double check all the linkage on the shifter.

Double Gunny MM2, my thoughts exactly. You could have incorrectly installed the shifter/linkage making it bind, or depending upon how far you took your shifter/linkage apart, it maybe all bound up, like cheese, due to length, etc.
I always mark my shifter linkage points to the shaft(s) to make sure it gets back on where it should be.

 

[CRMH Eagle]

Thanks guys! Appreciated. Will go re-check it right now. Hopefully it won't take long to figure out and a successful update will quickly follow.

 

[dcarver]

OH no, not the dreaded FJR shiftlinkitis syndrome!

 

[madmike2]

Thanks guys! Appreciated. Will go re-check it right now. Hopefully it won't take long to figure out and a successful update will quickly follow.

That's why I always take a picture of what I'm dis-assembling. I've been know to reinstall incorrectly.

Besides, the digital photos are so much better than the polaroids we used a looooong time ago.

[SIZE=8pt]Stapled to the work order so anyone in the shop could reinstall "interesting" throttle linkage, shift linkage, vacuum lines, etc., etc.[/SIZE]

 

[CRMH Eagle]

Is my assumption correct that I only adjust the little connect arm that is on the rod that goes into the clutch housing?

 

[FJRBluesman]

Is my assumption correct that I only adjust the little connect arm that is on the rod that goes into the clutch housing?

Did you disassemble that?
You may have only installed the whatzer dinger (shift arm) to the gear shift shaft incorrectly or I should say clocked incorrectly, IF you didn't take anything else apart. IIRC you can only clock wrong at the gear shift shaft and not the shifter pedal. Not sure of you can also just bind up the linkage on installation. You'd think I'd remember this since I only did it about 3K miles ago... :blink:

**EDIT**

If you didn't disassemble the shift rod from the joint rods, you only have a clocking problem of the shift arm. I don't believe the entire shift rod assy can get behind the bolt of the shift pedal, but ya never know. Check your manual or a parts fiche for proper fitment.

 

[CRMH Eagle]

I didn't think I took off the rocker arm connected to the rod that goes into the clutch housing. However, you guys will be surprised to learn the problem. When I lubed the joint behind the lever-foot wall, the one that connects the lever arm and the foot shift, I overtightened it and thereby it wasn't loose enough to allow for the "retract" from each clutch to push the lever back...thus after each shift the tightened joint kept the entire clutch from retracting.

Problem solved! It took over 2 hours but I'm glad this issue is resolved. Thank you guys for the advice. Next time I will mark the rocker arm location so I can prevent future problems.

Now after 5 weeks of waiting for maintenance and suspension upgrade, I CAN FINALLY RIDE!!!!!

 

[FJRBluesman]

Good on you! Lesson learned and you're back in the saddle! :yahoo:

 

[3dogs]

I didn't think I took off the rocker arm connected to the rod that goes into the clutch housing. However, you guys will be surprised to learn the problem. When I lubed the joint behind the lever-foot wall, the one that connects the lever arm and the foot shift, I overtightened it and thereby it wasn't loose enough to allow for the "retract" from each clutch to push the lever back...thus after each shift the tightened joint kept the entire clutch from retracting.

Next time you lube the shift lever take the wave washer out and flatten it with a hammer. This will give the shift rod in the side plate more clearance and it won't bind. I did this 70,000 miles ago and my shifter has never stuckl--lube it about every 10,000 miles.