996 shifting woes

[roadracer444]

Looks like my 2001 996 has a problem

yesterday while riding, I noticed the clutch seemed to slip while in 3rd gear and really getting on the throttle. I continued to ride it home(about 4 miles) and it was definately slipping in 3rd when I hammered the throttle. Then, it appeared that I got the bike stuck in a high gear and when I went to downshift, I got to neutral but not any lower. I was finally able to kick back into what I assume was 2nd or possibly 3rd. When I got to my garage, I kicked the shifter around a few and was finally able to get 1st and then neutral. I bled the clutch slave, thinking it was not properly disengaging the clutch, but that did no change a thing. When the bike is sitting there, off; it is near impossible to shirt it. When running, you literally have to stop the lever to shift to first gear, second is just as bad. I did not go above second cause I only went down the driveway and turned around. When I went to shift to neutral, it was extremely stiff and I was kepy going to first or second cause i had to push pull on the lever so much. Afterwards, I removed the clutch cover and pulled all the plates, which still look new (clutch only has a few hundred miles on it) but the hub appears to wobble slightly when i rotate it by hand. Tonight I'm going to break loose the large nut in the center and remove the hub and then basket and inspect them.

Any ideas from you guys ? Think I have a shift fork issue ? If I were to pull the stator side case cover, is there anything specific to look at, regarding the shift linkage ?

Thanks,
Tom

[roadracer444]

One other thing, the engine makes no funny noises that would lead me to believe a gear was chunked.

Also, A week ago when I was riding it hard (fast accelerations), I seemed to hit false neutrals between 2nd and 3rd. I adjusted the shift lever down thinking that I was simply not pulling up enough (i'm used to race shift pattern) but when I really rev it out and try to quick shift, it would not go.

Tom

[jaymags]

The basket nut has to be torqued well....Are your hub springs in good shape? Clutch plates stacked correctly?

[roadracer444]

Clutch springs and disks are new(only few hundred miles) and clutch stack appears correct. The slipping in 3rd gear only started yesterday, but something has apparently gone worse because now it will literally not shift gears without excessive force on the shifter. I know the cluch system is working because when I do get it in gear, the clutch lever does actuate the pressure plate and I can get the bike to move and stop. It's not like the bike is trying to pull out from underneath me with the lever pulled to the bar. It does disengage the pressure plate as it should.

I will verify nut torque tonight when I remove the hub and basket and re install.

Almost leaning toward something being bent in the shift internals.(but I honestly don't know)

Tom

[TomTom]

Start by taking the stator cover off, it's a good chance that the linkage bolt is loosened (at least the very first thing to check). If the linkage bolt is loose, get a manual and read how to adjust it, very simple. Good luck!

[chris steedman]

or the return spring on the paw arm is broken .on some bikes the sprag gear takes it out chewing into the spring. if this is the case just change the 0.5mm shim behind the flywheel to a 0.7.

[Rice]

Which clutch slave cylinder do you have in it? A PI?