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Old 09-26-2006   #1 (permalink)
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I just purchased this bike, an dthe shift lever doesn't want to return to its normal position after downshifting - it just stays down, an dI have to use the side of my foot to raise it into position so that I can downshift. The seller said it frees up if it runs daily. Any thoughts on identifying the problem and fixing it are greatly appreciated.

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Old 09-26-2006   #2 (permalink)
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i'm no expert, but that sounds triflin to me: like some little spring in the shifter mechanism or one of those wedge-shaped pins. you're going to have the gearbox cover off in this adventure sooner or later, can't hurt to check that first for simple stuff for old liquid gasket floating around, dirt, crud, or junk.
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Old 09-26-2006   #3 (permalink)
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It's likely the return spring in the shifter slot.

There are two of them, one for upshift, one for downshift, and they are squeezed into an arc-shaped slot under the retaining plate with 4 nuts holding the guts in.
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Old 09-26-2006   #4 (permalink)
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...hey Bill, I have a simular problem on my 69 100R. When down shifting I have to go from 2nd back to neutral to get back to 1st. Keep us an updated, I'm interested to see how complicated the shifter is to work on...

[ This message was edited by: Lumbee on 2006-09-26 11:48 ]
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Old 09-26-2006   #5 (permalink)
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The 500 is different from the 650....there are two stiff springs which center the shifter shaft and pawl carrier between shifts. They have little buttons on the ends and when you remove the two nuts and cover plate, they may try to leave at high velocity, keep a rag over it. The pawls are retained in the carrier by two cotter pins. My guess is that the pins are hammered and allow the plungers to protrude too far, hanging up in the camplate which is immediately above them. Remove the plunger cotters and plungers, and drill the holes for the cotters out to accept the next larger cotter pin. This will pull the plungers back down into place and keep them there longer. Once you get your manuals, you will see how the cover is attached and you will find this to be an easy fix.......unless the kickstarter spring retaining plate comes loose, then you will get to wrestle it back into place. I would order a new one, just for giggles, as they are often damaged where they fit over the flats in the kickstart shaft.
To get you started, pull the footpeg, probably the right pipe, if you want more room to work. Pull the kick lever. Remove the screws and nuts from the cover and remove it...leave the shift lever in place so that you can manipulate the shaft to free the plungers from the camplate slots and slide the cover out. Remove the lever once it's out and remove the shaft/pawl carrier to work on it.
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Old 09-26-2006   #6 (permalink)
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Many thanks for the advice. I've rebuilt a couple of engines, but never had the intestinal fortitude to tear into a gear box. I guess I'll take a stab at it when the snow hits.
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Old 09-26-2006   #7 (permalink)
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as long as you drain the oil before you take off the outer cover, you're going to be fine!
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Old 09-27-2006   #8 (permalink)
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Yep, yep, I forgot it wasn't a 650 we were talking about.
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