New drz, trans issue already :/

[thumpin bananna 01]

So new to the forum looks good so far! Anyway just bought a 2001 drz 400s driving it home from my friends going 55 in 4th gear I go to down shift to go around a corner and when I click the lever it springs down and back up but doesn't shift into 3rd. It will go into 5 but never into 3rd or any lower gears. Any ideas?

[skumby]

How is the oil? Overdue for a change?

[thumpin bananna 01]

He did regular changes with synthetic every 3k and when we looked at it yesterday it was still good. Golden color

[Gsxrstuntdrz]

Bent shift fork would be my guess

[thumpin bananna 01]

That's what I heard. I take the right side cover off and it's in there right? And how bad is it to get to those? But I can go into 5th so the forks for 1-3 are bad?

[Erik Marquez]

Possible shift spring

#24

Possible deeper in the trans like shift forks or damaged gears (engagement dogs) 

 

but start simple

 

Are you shifting completely, firmly?

Pop off the right cover and look at that shift stop arm and spring

 

[thumpin bananna 01]

It was shifting firmly up to that point. Between 4 and 5 aren't sloppy shifts at this point. Thanks for the pictures they are going to help!

[Erik Marquez]

That's what I heard. I take the right side cover off and it's in there right? And how bad is it to get to those? But I can go into 5th so the forks for 1-3 are bad?

You can not access the shift forks without splitting the case

[thumpin bananna 01]

But I can't visually inspect them with it not split?

[Noble]

No.  You can not see the shift forks at all with the center cases together.  But I would not assume the worst.  No reason to suspect a bent shift fork.  They do not bend easily.  Check out all the shift indexing mechanism accessible with the clutch removed.  Likely you will find the problem there.  The fact that it will not shift into 3rd or lower it is reasonably certain the problem is in the indexing.  I had a similar problem years ago and found a short piece of nylon wire tie in the indexer.  No doubt something of my own doing.

 

Oh yea, look for a rock restricting the movement of the shift pedal or the pedal loose on the splines for misaligned hitting something.

Edited April 20, 2014 by Noble

[thumpin bananna 01]

Sounds good. I'll check out those parts indicated in the pictures. It was for sure my fault. I really hope I dont have to split the case.

[thumpin bananna 01]

T

Think I found the issue. That little thing the screwdriver is near doesn't spring out on it's own well when I shift. So the springs behind it must be bad.

[Noble]

That would do it.  The spring might be broken or the pusher may be jammed with some foreign material.  Further disassembly will reveal

[thumpin bananna 01]

I'm glad I finally know it's not the transmission and I don't have to split the case. I think it's called the pawl. I will order parts tomorrow and should be back on the road next week!

[thumpin bananna 01]

Anyone ever changed that part? I was reading in the book the shaft could fall into the case? Once I undo the bolt?

[Spud786]

I wonder what oil or change interval the other owner used, cause looks like a little sludgey in there. Anyway find out his method and do the opposite.

[Erik Marquez]

Anyone ever changed that part? I was reading in the book the shaft could fall into the case? Once I undo the bolt?

Shaft? The shift shaft? Then no.. it can not fall anywhere.

 

when you remove part 13, parts 10, 11, 12, 15 & 17 all come free, and yes, any of those parts could get into the case if you let them... so don't let them

 

 If you have a pawl spring fail.. that would be a first I have ever heard of on this motor.. so possible? Sure., likely? NO.

 

I would not order any parts till you remove the "lifter, gear" part 13 (you will need a impact screw driver and a #3 cross tip bit)

Then check parts 11, 12, 15 & 17 for serviceability and free movement. It could be debris causing a pawl to jamb as suggested by Nobel .. But outright failure of one of those parts is not likely 

[thumpin bananna 01]

I won't but the book was saying that the shift shaft could fall out. But I doubt that. If stuff falls in the case that's no big deal it's not like the case is deep and I can't fish them out. Keep in mind if I sound like a idiot it's my first time inside a transmission of any kind. Lol

[Erik Marquez]

I won't but the book was saying that the shift shaft could fall out. But I doubt that. If stuff falls in the case that's no big deal it's not like the case is deep and I can't fish them out. Keep in mind if I sound like a idiot it's my first time inside a transmission of any kind. Lol

The shift shaft can not "fall into the case" (what "book" ? are you referring to?, not the OEM service manual .. )

 

The shaft SLIDES out of the case from left to right. once the snap ring on the left side is removed, yes the shift shaft can slide right and "off" or out of position,, but it simply slides back on.

[thumpin bananna 01]

Not oem and aftermarket service manual. I have no worries I got this far so it's just r/r at this point