Downshifting Probs

[indr]

Upshifting is fine. To downshift, I have to really slam my foot on the gear change lever.

When I rebuilt the engine, I changed out both springs on the gear change mechanism.

[tubarney]

How did you install that big spring? Was it like this?

Are the internals of the neutral bolt installed?

[sLick415]

Since were on the topic (really don't mean to thread jack), what's part# 92027 for?

[indr]

Originally Posted by tubarney

How did you install that big spring? Was it like this?

Are the internals of the neutral bolt installed?

Yes. Neutral bolt? What is that?

[indr]

Originally Posted by sLick415

Since were on the topic (really don't mean to thread jack), what's part# 92027 for?

It's a plastic spacer that goes on the outside of the crank-case. It sits between the crankcase and the sprocket cover (I think) on the shift shaft.

[tubarney]

Originally Posted by indr

It's a plastic spacer that goes on the outside of the crank-case. It sits between the crankcase and the sprocket cover (I think) on the shift shaft.

Yeah it a spacer that matches the internal diameter of the big spring. So the spring has less chance of bending out of shape.

[tubarney]

Originally Posted by indr

Yes. Neutral bolt? What is that?

This thing. http://www.ninjette.org/forums/showt...t=neutral+bolt

Also make sure the teeth that turn the drum are properly located. I'll get you a photo.

[tubarney]

Here how it should look.

I had problems shifting mine when I put it back together. Turns out it was the neutral bolt and big spring.

[indr]

Originally Posted by tubarney

Here how it should look.

I had problems shifting mine when I put it back together. Turns out it was the neutral bolt and big spring.

Thanks for that. I'll open up the clutch cover and see how it looks. I'm pretty sure I got it right though. Both springs were new, and the teeth hooked on fine.

Also, when you pulled apart the shift shaft, did you notice any side-to-side play between the upper and lower teeth like this?:

[indr]

Originally Posted by tubarney

Here how it should look.

I had problems shifting mine when I put it back together. Turns out it was the neutral bolt and big spring.

Also, what was wrong with your neutral bolt? I pulled mine out along with the little cylinder. They seemed fine.

[indr]

Originally Posted by tubarney

Yeah it a spacer that matches the internal diameter of the big spring. So the spring has less chance of bending out of shape.

You mean it goes under the spring? I left mine out. It sits between the sprocket cover and the crankcase as a spacer.

[tubarney]

Originally Posted by indr

Thanks for that. I'll open up the clutch cover and see how it looks. I'm pretty sure I got it right though. Both springs were new, and the teeth hooked on fine.

Also, when you pulled apart the shift shaft, did you notice any side-to-side play between the upper and lower teeth like this?:

Yes you will get side play. That is normal. I was wondering about that to. I have a second engine and it was the same. Mine is like that and shifts perfectly after I sorted out the spring and neutral bolt.

[tubarney]

Originally Posted by indr

Also, what was wrong with your neutral bolt? I pulled mine out along with the little cylinder. They seemed fine.

I didn't have mine installed. You can remove the internals so if they were missing it would be the same as not having it installed.

[tubarney]

Originally Posted by indr

You mean it goes under the spring? I left mine out. It sits between the sprocket cover and the crankcase as a spacer.

The spacer goes on the inside of the big spring(where I am pointing the knife). You have to take the shaft out of the engine to put it on.

note: the shaft is not pushed in all the way. The Spacer is not installed!!

It could be causing the spring to bend out of shape.

The spacer stops the spring from moving around on the shaft.

[tubarney]

Also, If you haven't already, on the other side of the engine check that your linkage is not hitting your kickstand or something.

[indr]

Originally Posted by tubarney

How did you install that big spring? Was it like this?

Are the internals of the neutral bolt installed?

This was the problem. I had the ends of the springs installed crossed. Not like the photo. Fixed it. I had yet to take it out for a ride, but now, there is definite tension on the shift lever. Before it was sloppy with no "springiness."