eastcoasthopper Posted January 1, 2008 Report Share Posted January 1, 2008 Sometimes when I upshift my 2006 trial 2.9 the shift lever stays up. I can't upshift again until I tap it down. There is nothing rubbing on the outside or the inside. I took it all apart, and it looks like the 'cog' that moves back and forth on the end of the shifter gets hung up. I tried to file it down on the edges, but either my file is crap or it's hardened steel, because it didn't do much. Before I take it apart again, I was wondering if anyone else has had this problem, and what they did about it. Thanks. Quote Link to comment Share on other sites More sharing options...
betapete Posted January 1, 2008 Report Share Posted January 1, 2008 return spring worn? Quote Link to comment Share on other sites More sharing options...
eastcoasthopper Posted January 1, 2008 Author Report Share Posted January 1, 2008 return spring worn? I don't think so. It's really stuck when it sticks. The spring feels strong. The bike wasn't ridden at all in 2006, so there's only one season of riding on it. Quote Link to comment Share on other sites More sharing options...
copemech Posted January 2, 2008 Report Share Posted January 2, 2008 If you feel as though that is what the problem is, and all esae is well and in proper alignment, I think you may try to polish it with come crocus cloth(strip of sandpaper) from your auto parts store, or the abrasive roll on a Dremel tool. Seems I did have one to do that, maybe the '05 bike, but it soon wore in on its own. Hope that helps Quote Link to comment Share on other sites More sharing options...
sherpa Posted January 3, 2008 Report Share Posted January 3, 2008 try loosening the screws around the right side cover, particularly the ones around where the shifter shaft comes through. If this solves the problem, add another right side cover gasket. Quote Link to comment Share on other sites More sharing options...
eastcoasthopper Posted January 13, 2008 Author Report Share Posted January 13, 2008 try loosening the screws around the right side cover, particularly the ones around where the shifter shaft comes through. If this solves the problem, add another right side cover gasket. I don't think that is it. I can get it to hang up with the whole clutch off! I've been so busy riding, I haven't had time to take it apart again and try the suggestions. Thanks to you all, I'll try them when I have time. I hate to stop riding long enough to work on my bike! Jareth ) Quote Link to comment Share on other sites More sharing options...
shercosi Posted January 14, 2008 Report Share Posted January 14, 2008 Have you also checked that the gear selector shaft is straight. You may have bashed gear lever on a rock etc remove shaft completely from engine and check with a straight edge, this is rare but also possible Quote Link to comment Share on other sites More sharing options...
eastcoasthopper Posted January 27, 2008 Author Report Share Posted January 27, 2008 Have you also checked that the gear selector shaft is straight. You may have bashed gear lever on a rock etc remove shaft completely from engine and check with a straight edge, this is rare but also possible WOW, you'd have to do something really amazing to bend this shaft, it's behind the chain! Checked it and it looks good, no surprise here. I have the shaft out, and it feels like the part that hooks to the drum pins, that springs in and out on the part that is welded to the end of the shaft, is dragging. Seems like it has just enough of a burr to hold it back occationally. Seems really weird, but that's the only thing I can find. I can make it hang up with the clutch off, and no shift lever. There's nothing else in there to hold it. I may just replace the shaft and see what happens. Jareth ) Quote Link to comment Share on other sites More sharing options...
copemech Posted January 27, 2008 Report Share Posted January 27, 2008 Maybe you can work some lapping compound into it and work it to a polished state? Or possibly just take a BFH and beat it into submission! Quote Link to comment Share on other sites More sharing options...
eastcoasthopper Posted August 18, 2010 Author Report Share Posted August 18, 2010 Hard to believe, but I've beat the crap out of this bike, even cracked the frame, and the shifter STILL hangs up. I would have thought it would wear in by now. Guess I'll take it apart this winter and have another look. Quote Link to comment Share on other sites More sharing options...
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