S3 2009 Stuck In Gear Can't Downshift From 5th

[H0rus]

Coming home from a very long ride noticed it was hard to downshift from 5th until I was stuck in the gear. That happened some 20miles from home which is good. To get the bike out of gear I need to turn it off and slowly move back and forth until I found neutral. I avoided to get from 4th onwards but last miles to home noticed that 4th was also problematic but not always. At the first light problem was also finding neutral. Problem appears only when downshifting. 2 years ago I also took off the gear linkage and replaced with a small shift lever. Next thing that I've done is new clutch cable, slack adjusted by manual. That didn't solve the problem. Oil was changed 500miles ago with the same that I'm always using, level is fine. Took the clutch cover off and started inspecting things. What I noticed so far is,

1. Outer clutch metal plates are slightly colored purple, friction plates measured and are all like new inner and outermost 3.80mm and others 3.30mm.
2. Outer drum seems to have a lot of play

Took the outer drum out too and started inspecting things but can't see anything wrong. Any idea what might be from the pictures and videos? Thanks

VIDEOS
YouTube

 

[brooke]

Horus ..
Sounds very much like what my Tiger did . Downshifting was never great and got worse to a point where it wouldn’t do it . Perhaps the end of the shift rod is bent and not re centering to the proper position. This happens over time if you get a little heavy with the boot on down shifts . I replaced mine and after a year of break in it started shifting like it should have when new . Looking back I believe there was no need to replace it and bending the part back to it’s original shape would have worked . The metal could have been thicker , in my opinion .

 

[brooke]

Looking at your video, your set up is very different from the Tiger , much more complex . Looks like the part which moves the pin wheel is worn ( your red arrows ) and the spring ( don’t believe the tiger has one ) is allowing it to disengage the pins . But I think your pix do show things are not getting back to a neutral position after each shift . That spring seems very light for the job it is expected to do .

 

[CarlS]

I had that problem with my 2012 Tiger 800 XC. In my case it was the shift return spring broken. Triumph makes a whole kit to repair it which includes a new shift return spring. Other Triumph models have experienced the same problem. Here is a link to a thread on the subject.

https://www.triumphtalk.com/threads/service-bullentin-gear-selector-return-spring.17777/

 

[H0rus]

Looking at your video, your set up is very different from the Tiger , much more complex . Looks like the part which moves the pin wheel is worn ( your red arrows ) and the spring ( don’t believe the tiger has one ) is allowing it to disengage the pins . But I think your pix do show things are not getting back to a neutral position after each shift . That spring seems very light for the job it is expected to do .

I will replace the whole Mechanism Assy Pivot and Detent Wheel just to be sure...

 

[brooke]

I will replace the whole Mechanism Assy Pivot and Detent Wheel just to be sure...

Sounds like a plan . Best of luck .