accidental upshifts

ironknobby · Nov 23, 2009

quite a few times recently I have upshifted while on the throttle unintentionatly.My new boots are stiff and bulky,I am going to rotate the gear shift a spline or two,hope that helps.I havent noticed any grinding,just slams into gear,you think I hurt anything?

CrazyTed · Nov 23, 2009

Many of us shift without the clutch under power and never have a problem. In fact, Rich Lafferty teaches that at his riding schools here in the US. No clutch for shifting at all, only for when you are braking hard and the bike may stall.

tazer · Nov 23, 2009

Hi Guys,

Hey ironknobby I have done the same thing a few times and it sounds pretty ugly when it happens, makes you wonder if you have done damage.

You have made me feel a little relieved CrazyTed but I still don't like doing it. :?

Steve

bushmechanic · Nov 23, 2009

on the old models thumping into 1st , 2cnd, 5th and 6th is OK

3rd and 4th have a weakpoint where the groove is machined for the shift fork

as long as the shift is quick and it does't get stuck between gears I think its OK,

if it gets a false nuetral and then slams back in when the motor spins up its no good

this one was worn out and had smashed the circlips off the shaft so fair enough but I did another one on new gears 20 hrs old.

I cut the lever end shorter when I got the bike and have just moved the lever up a slpine, the engine is strong enough now with some mods and a taffy touque cam not to have to change gears much. the other mods I did to the shift star work well too.

the new model has a better profiled shift star and a stronger detent arm spring but the 3rd and 4th sliders and their circlips still have the same weakness.

bushmechanic · Nov 23, 2009

and the other one this time on an almost new gear

this time the circlips were locked on with special locking stop discs, all that did was make the gear take all the impact, its nearly ripped all 4 dogs clean off. circlip did not budge.

one was 3rd one was 4th they're the ones to be careful with.

have ridden dirt bikes for bout 25yrs never broke a gearbox before

not 100% certain but I think the KTM/berg gears are hardened a tad more than the jap ones so the wear surfaces on the gear teeth last longer but they aren't as tough for taking impacts through the dogs. and then these 2 gears that slide into 3rd and 4th have a design problem with the groove for the shift fork.

tirebiter · Nov 23, 2009

ironknobby said:
quite a few times recently I have upshifted while on the throttle unintentionatly.My new boots are stiff and bulky,I am going to rotate the gear shift a spline or two,hope that helps.I havent noticed any grinding,just slams into gear,you think I hurt anything?

What size boots do you wear?
If your a big foot, you might wanna look into a longer shift lever- but it's probably the new boots that's causing the problem. I can never seem to find the rear brake and have a hellufa time shifting with new boots.
Make your shifting & rear braking a deliberate task till the boots break in.
In other words, pay close attentiion to where your feet's is.

pear · Nov 23, 2009

RE: Re: accidental upshifts

I also find this to be a problem. As was stated seems to be a 3rd and 4th gear thing if getting tired and not paying attention. Has me concerned, especially after seeing those pictures. My boots are well broken-in Alpinestars Tech 10s. This is on a 2010 FE 450.

bushmechanic · Nov 23, 2009

RE: Re: accidental upshifts

ha sorry everyone these pics are from the old model

different gearbox

the new model has a better profiled shift star and a stronger detent arm spring but the 3rd and 4th sliders and their circlips still have the same weakness.

the same principle applies though; if it thumps into gear hard enough at the wrong time it will break something eventually.

the ktm 450 and 505 sx gearboxes are really nice. the sliding is done by shift rings so the gears can stay still. the gears don't have to slide or accomodate the shift forks so they can be made stronger. apparently there are even people putting these gearboxes in their jap bikes.

Taffy · Nov 24, 2009

RE: Re: accidental upshifts

you'll know when the dogs are going when it starts to find false neutrals just after a shift....it makes you think you didn't kick it into the next gear hard enough - but you did!

regards

Taffy

F+ · Nov 24, 2009

RE: Re: accidental upshifts

I have made mine go click also, a couple realy big ckicks at that. I wear SiDi crossfires and 2 pairs os shocks. I am wearing the toe and the shifter pedle out pretty fast. (I'll post a pick later). Any one else ?

I went down in a river in the snow the other day. I even dunked my face. I don't know why it wasn't frozen. I was wearing a polaris bib and Klim everything else. No water penitration anywear. Up and gone within seconds only broke a bark gaurd (ripped out a bolt) and all in front of a bunch of guy's stacking hey no less. Just had to share. It was sweet.

F+ · Nov 25, 2009

I could have done without knowing that Taff, I've hit a couple.
Thats about 3000 miles on both boot and shifter.

bushmechanic · Nov 26, 2009

I forgot to mention the spring that returns the shift lever to centre could also be either doubled up or uprated to help stop the lever being bumped

the negative thing about uprating the detent or shift lever springs is that it gets harder to shift

steve · Nov 26, 2009

I've cut about 10 mm off the end of my gear lever, 2 rings, and having the pegs rearset makes for more room with my size 13 Tech 8s

My gear change technique for many years is to continue to apply toe pressure on the gear lever until the clutch is released, if using the clutch, and drive is back on. This virtually guarantees a clean, neutralless change every time. Don't just tap/bang/stomp the lever and hope, press firmly, and hold! Works every time on all bikes.

Steve

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