Problems shifting up to higher gears

[Nightmare]

The issue I am experiencing is when moving the shift lever up to change to a higher gear the lever seems to get stuck (or more accurately, hitting a bump/stop) ABOUT half way; I can keep pushing up a bit harder and get into the next gear where if I do that everything is fine. However, if I don't notice that I didn't fully shift into the next gear (I release the shift lever and clutch at the "bump") the bike will pop out of gear. I haven't had any issues shifting down, the shifts are smooth and always go into the gear I want and never pop out of gear.

I spoke with the head mechanic at a local shop I trust and he suspects the issue is related to part #13 (Honda Spring Shift Return - 24651-MBB-000) since the clutch seemed to be good and the issue is only with shifting up.



I've only owned the bike since October and when I got the bike it was in need of some maintenance, specifically related to this issue, the clutch fluid was HORRIBLE (it had turned to a gel) and shifting from 1st to 2nd was hit or miss. I have replaced the entire clutch line with a bit longer stainless steel braided line, new fluid and a new clutch slave cylinder. I cleaned and greased the bushing for the clutch lever and the free play at the lever is minimal. I have also removed, cleaned and greased the joints for the shift lever.

I believe the clutch is in good shape, with the bike on the centre stand and in gear I can stop any wheel movement with 1 finger and the engine RPM never jumps under load (no sign of clutch slipping).

SO my questions are:
-Any idea what the problem actually is? (The return spring, shift forks, shift drum?)
-Is it possible to repair this WITHOUT dropping the engine?

 

[dwalby]

I think its a common issue to get road gunk in the shifting mechanism that makes it more difficult to shift. Clean it off and lubricate it, see if that helps.

 

[Nightmare]

I was planning on pulling the shift lever and linkage to check it over for any signs of wear/binding since its easy to do (compared to dropping the engine). I'm not optimistic that this is the issue since it was cleaned and greased within the last 2000kms.

 

[Larry Fine]

I suggest adjusting the shift lever down a bit, so less up-travel of your toe is required.

Perhaps your legs are longer than those of the previous owner, tilting your toes down.

 

[ST Gui]

I'm not optimistic that this is the issue since it was cleaned and greased within the last 2000kms.

That could be disappointing as it's a common source of shifting problems. I'd posit that upshifts would be problematic before downshifts as the problem develops. But a cleaning and lubing with in 2000km would seem to make it less likely.

Another thing might be that it's a tooth higher or adjusted a skosh higher than when you took it off to clean and lube it. This can make an upshift a little tougher without some deliberate compensation. As Larry suggested adjusting it down could help if your footwear will still clear.

When I put GoldWing pegs on my 1300 my foot position dropped an inch. I missed a few upshifts until I made a deliberate effort to "preload' the shift lever and "follow through" till I caught the next gear. I should adjust the linkage though.

 

[Nightmare]

I had adjusted the position of the linkage, basically it feels like I completed the shift like, the lever moves freely, then feels like I hit a stop, but this is only half way through the lever travel. I do wonder if the issue is JUST with the shift linkage, I'm trying to remember back to last October when I got the bike. I was able to take it for 2 long rides and the only issue I remember was shifting from 1st to 2nd, but that felt like another lifetime ago.

 

[Larry Fine]

Where along its travel from fully pulled to fully released is the clutch lever's engagement zone?

It should be nearer to fully released, otherwise you are not releasing the clutch fully when pulled in.