Will not shift to 3rd gear

gvnick · Jun 7, 2010

I have an 06 FE450, street plated. This weekend the transmission mis-shifted a couple times from 2nd-3rd gear. I would upshift and it would still be in second. It got bad on my ride home on the street, it took 5 tries to upshift before it finally grabbed the gear. Once it got third, everything was fine. No grinding noises, just no clicking feel as I pulled up to 3rd gear.

Any ideas? Thanks for any help.

bushmechanic · Jun 8, 2010

you can check the external stuff underneath the clutch basket

if thats all OK then you need to split the cases,

use Kawasaki circlips when you rebuild the gearbox (part nos in my gallery). If one of the shift forks has had a hard time replace it even if it looks OK, also replace the shift fork slider shaft and check the shift drum for damage.

I think the detent arm spring and the return spring on the gear lever are too soft. the shift star is also a different profile to most bikes being very pointy where most have a double profile to each tip.

I put in a stiffer detent arm spring and reprofiled the star, shifting is harder and slower but more positive and I have had no problems since.

Will not shift to 3rd gear

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