My 96 fe501 got stuck in neutral, i took the clutch cover off and de-burred the star and shifting fork. I noticed that the shaft that tbe clutch slides onto spins freely for 90% of its revolution but then feels slightly tight. If i continue to spin the shaft it frees up but then tightens slighlty at the same point of its revolution. If i try to change gear when the shaft is in its tight spot it wont change, but turn the shaft a little till it frees up and the gear shift starts to work again. Any ideas? All replies greatly appreciated
So i filed all the burrs off the shuft fork, star and filed the clutch basket smooth. Put back together and with no oil in and bike obviously not running it selected gears fine. Soon as i filled it with castrol semi 10 40 oil it wouldnt change again. Dropped the oil and it started working. Used thus oil for a while but now my husa has decided it doesnt like it. Any suggetions of what should be used please. Odd how it worked fine for about 5 hours with castrol then decides its not happy. Surely it must be the oil, maybe too thick? Thanks
Ok, il take the clutch cover off again and maybe polish the shift fork assembly? The shift fork did have a slight bend on one of the forks. I filed it down but thats all. Thanks for the reply, and thanks for sending the grips and air filters so quickly. Much appreciated
Joined Nov 2001
17K Posts | 774+
Ely, England
yes when the plates slide past each other you have 4 'arrow head halves' two on each plate. where they pass each other needs the edge skimming back. I have learnt to slide mine up and down on the wall grinder along its side face.
Alison's quite good. I don't know where I'd be without her.
regards
Taffy
Alison's quite good. I don't know where I'd be without her.
regards
Taffy
So after 2 days of frustration, 3 clutch rebuilds and lots of de-burring i figured out what was causing my berg to stick in gear. It was the oil drain plug! When i dud its first oil change i noticed that the oil drain plug was loose. Thought nothing of it and dropped the oil and nipped it up. Turns out that when the plug is screwed in hand tight it must rub up against something and stops the gear dhift working. Back it off 2 or 3 turns and hey presto! It works again. On the plus side the gear change is now smooth as silk and finding neutral is now a breeze. What would cause this taff? And should the plug have a washer or seal on it? Maybe an aftermarket plug? Its just a straight threaded dowl Bout an inch and half long. So its now tbread locked in the correct position. Thanks for the suggestions though taff 
Joined Jun 2007
4K Posts | 1K+
south east WA Australia
that's a new one Rambo !
the first thing i do when the box is weird is drain the oil and look for bits of metal with part numbers on them
once I looked in the drain hole and saw a piece of gear dog so big it wouldn't fit out the hole
next port of call is to try and turn the shift drum and shift star manually without the gearshift lever or mechanism
then you can isolate where the issue is, if the shift drum is difficult to turn then the problem is internal not external
the first thing i do when the box is weird is drain the oil and look for bits of metal with part numbers on them
once I looked in the drain hole and saw a piece of gear dog so big it wouldn't fit out the hole
next port of call is to try and turn the shift drum and shift star manually without the gearshift lever or mechanism
then you can isolate where the issue is, if the shift drum is difficult to turn then the problem is internal not external
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