I have an intermittent stuck gear on my 2005 Tiger 955i and I would appreciate any ideas or diagnostic tips to help resolve this. Its happened twice. These are the symptoms:
- If I ride around very gently I don't tend to have a problem.
- If I accelerate a bit more quickly, but by no means harshly I find that the gear shift mechanism can get stuck somewhere at the point I change into 4th. Its possible my description is out by 1 gear as I don't tend to be making notes when it happens. The gear shift pedal will not move up or down and feels stuck solid. Both times this has happened, I've been able to get it out of this situation by releasing the clutch moderately rapidly and it has then become unstuck.
- I fully use (or intend to at the time) the clutch for shifting. I don't do clutchless shifting, but previous owners may have.
- I'm new to riding so my shifts aren't buttery smooth, I try my best to rev-match as best I can, but I know I don't do it well.
- I've never had the bike "drop out of gear while accelerating". Problem occurs when shifting only.
- When the bike is in neutral with the clutch out, it sounds a bit rougher than with the clutch in, but not a great deal. Not sure if that is normal or not.
I believe the clutch is good. I say this because I've had the outer clutch basked cleaned up by a mechanic as I had trouble getting it into neutral previously. It would jump between 1st and 2nd instead of going into neutral at a stand-still. That now seems pretty good and changing gears just seems a lot less agricultural since the clutch has been cleaned up. The stuck gear problem happened once before I got the clutch cleaned and once afterwards, so it was neither a cause or a fix.
Whilst I intend to fully pull in the clutch, its possible I didn't make it all the way, being inexperienced. Would that possibly be a cause?
I kind of get the impression that the mechanic doesn't want to deal with this problem and to be honest I'm not sure I want to hand over another wad of money with no guaranteed fix at the end of it. I'm starting to resign myself to the fact that I'm going to have to try and fix this myself. I don't have any experience fixing bikes, so opening up the engine case is a daunting prospect for me. I'm also mindful that if I screw this up, the bike could be dangerous, so I'm going to be very methodical and cautious. Were I to do this, are the suspect parts i.e. bent selector forks, worn drum etc fairly easy to identify as being "bent or worn" or can they be out by an amount not noticeable to the naked eye and still cause havoc?
Is there a way to open up the engine so that all the bits don't fall out as I do it, before I can record where they all go, like the roadrunner cartoon when the coyote's acme do-hicky blows up and all the springs fly out! What I mean is, should I lay the engine on its side or something so that the shafts stay in place by gravity. I've searched you-tube and I'm really amazed that I couldn't find a video that starts with the words "My names Derek and today I'm going to take apart my Tiger 955i engine" That would be really handy.