okay, i've gone over this thing with everything i got...

bike is VERY hard to shift, sometimes i can't even get out of 1st.... also hear some whining

anyway....i park the bike, get it in first, and can't even move the bike into neutral...but when i shut it down, it'll shift fine

i've adjusted the clutch at the primary, adjusted at the cable, and even replaced the bottom ramp in the tranny side because there was a wear spot in one of the grooves

i've done everything.... any advice or direction would be greatly appreciated!

thanks in advance, paul

 

What are you working on?

 

It sounds like to me , that the friction plates and the steel plates are to close together they need a little more space when you pull the clutch cable in I would turn it in a 1/4 turn the rod and I think that would do the trick .

 

Overfilling the primary can cause all these issues. With the bike standing up straight, the oil level should just touch the very bottom of the outer clutch ring. If your running SE20-50 syn, I'd change it out for straight dino oil in 15-40 weight.
Cable operated should be set with approx 1/16th" play at lever. If I remember right, they changed the ramp system to get a lighter clutch pull back about 06, that means the clutch pull doesn't move the clutch plates as far to release them. Adjustment becomes far more critical because of it. FWIW Fastrider124 Good luck

 

found it...

 

The infamous spring plate...

Suggest you go back together with an extra plate clutch kit from Barnett, Energy one or Alto Red, this will eliminate the spring plate.

 

Dan, if i had to take out the oil bag, starter, exhaust, primary cover, tranny side cover, and battery one more time to peek inside the tranny or re-adjust the clutch and cable one more time i was gonna lose my mind

it HAD to have something to do with the clutch....so ordered the spring compressor from George's, and sure enough the debris you see in that pic is what fell out when i pulled the pressure plate off

indeed, replaced everything with an updated Barnett extra plate kit that eliminates that spring plate ....shifts smooth as silk....couldn't be happer

 

Well done. Some mess you found there. I received my Barnett extra plate set just a short while ago and plan fitting it soon.

 

you're going to really like it, gr

also, you'll find that they tell you to use Type F -ATF to soak friction plates for a few minutes... wasn't sure if I was to use same for primary fluid, but Chance from Barnett confirmed, and so that's what's in my primary....works great!

 

That's useful to know, thanks. I must read the instructions! This is actually for my dresser below, which also needs a new starter, so I am bracing myself. I'm trying to create the space to start work, in my very small garage!