Shifter pushed into transmission during oil change. now the bike wont shift gears and makes a horrible sound when started. AHH!

Instructions

1.
The 2nd gear lockout is, a mechanical speed sensing mechanism. It doesn't care if the engine is running. You bypass it by scooting the bike forward, about 5-6 mph, while shifting the transmission into 2nd gear.
2

Stand on the left side of the bike, with the ignition "ON" and the transmission in neutral.
3 With your right foot on the ground, behind your left foot: place your left foot on the left foot peg, with your toe under the shifter; squeeze in the clutch.
*4.Scoot the bike forward about 5-6 mph, with your right foot, and shift the transmission into 2nd gear, with your left foot. If you accidentally go into 3rd, or some higher gear, you can easily shift back down into 2nd, without further movement of the bike.
5.To start the bike: Apply the choke if the engine is cold. Squeeze in the clutch and push the bike forward, both feet on the ground, about 8-12 mph. Release the clutch until the engine start
6
As soon as the engine starts: squeeze in the clutch and shift the bike into neutral.

Without being able to see and mess with the bike a bit, I would guess that you have a shifter pawl spring broken in your transmission. It's either the return spring or the spring on the pawl itself. To test the spring, start from the "neutral postition" of the shifter. Regardless of the gear the bike might be in, when you are not pushing down on the shifter or lifting up on it, it is in the neutral position, where it normall sits. Now, using your fingers push down on the shift lever until you feel the transmission start to shift, you feel a resistance. Stop right there, do not shift the gear but allow the shifter to return to the neutral position. Now, lift the shifter with your fingers until you feel the resistance of the transmission getting ready to shift. What you are feeling for is the resistance of the shifter return spring. Does it feel the same in both directions? If not, the spring is broken. If it does, then the problem is something else.

Still if the transmissio will not shift into a particular gear, something is wrong inside the transmission and you'll have to go into it to find the problem most likely.

Good Luck
steve

If it won't shift into ANY gear, this is not good. If the bike has been sitting for two years, even if it has be started and allowed to idle, this probably did not warm the transmission lubricant enough to get any water out of it. Water will get into the transmission by condensation on the inside of the aluminum gear box.

My suggestion is first try to shift the transmission by rocking the bike backwards and forwards while applying pressure to the shifter. If this doesn't result in a shift. Check the shifter, the linkage, and the shift lever back at the transmission for freedom of movement. If all moves freely but the transmission still won't shift, I would suspect that the shifter cam in the transmission is locked up.

Drain the transmission and look for water or something that looks like chocolate milk. If you see this, it's rust. The shifter cam, just under the chrome top plate of the transmission may be rusted and locked up. Dissassembly of the transmission may be required. Just how far you'll have to go is dependant on what you find under the top plate.

Good Luck
Steve

No, engine oil would have no effect on the transmission. When a big twin will not shift the problem is usually in the transmission. To test this, try to shift the transmission from first to fifth gear without the engine running. Rock the bike forward and backwards while trying to shif the gears. If you can go all the way up and back down, the transmission is alright.

If not and you can only shift from first to second, check the shift lever where it attaches to the shifter pawl shaft. Make sure that it is tight and not slipping. If it is tight and not slipping, it is probably your shifter pawl return spring.

With the transmission in neutral, lift the shifter lever with your hand until just before it shifts. Feel the spring tension. Now, depress the lever until just before it shifts into first gear. Does the spring tension feel the same in both directions? If not, the spring is probably broken. Do NOT start the engine if this is the case as further damage can be done to the transmission. To repair this requires a major disassembly of the transmission and is usually beyond the capability of those other than trained mechanics.

Good Luck
Steve

OK, for a beginner in the world of 18 speed bikes, put the chain on the big sprocket up front, it should be about 46 teeth, make sure it is center and doesn't make noise, if it does, adjust it just a hair either way, now, the rear, put the chain on the big sprocket in the rear, make sure the front didn't start making noise, if it did, adjust it again. You are now ready to take off, in low gear, as you start out, it is easy to pedal, soon you will be peddling air, shift into second gear in the rear only, don't touch the front. Just a little push with the thumb will make it shift, now were going faster, easy peddling, shift into 3rd, then 4th, etc, coming to a stop, down shift the back sprocket back into low gear (big sprocket) and be ready to take off again. Soon you will be shifting that thing like a Ferrari! The front sprocket, will be used for moderate terrain, wheelies, and mountain climbing, that will come later, learn how to shift the rear first. As each gear climaxes, hit the shifter, it will get smoother as you go, and keep the chain quiet, no climbing on the next sprocket or falling out of gear. Hope this helps.

With your bike not running and the transmission in neutral, use your hand a slightly lift up on your shifter. Don't actually try to shift the transmission into a gear, just lift the lever and feel the spring tension on it. Then push down on it as if to shift into first but don't actually shift the transmission into gear. The resistance in both directions should feel about the same. What you checking here is the shifter pawl return spring. On the five speed transmissions behind Evo engines, they were bad about breaking. If you've got sring tension trying to return the shifer back to the neutral position from both directions, you're fine.

Now there is another little spring on the shifter pawl inside the transmission. That may have messed up. I don't know whether your problem was just a one-time thing or if it's something that is going to be recurrant.

Either way, I would suspect a problem with the shifter pawl. If you replace it, replace it shaft and all. It is a complete teardown of the transmission to replace it. Just ride the bike until it screws up completely unless you are sure thats what the problem is.

Sounds like bent shifting fork which is expensive. If you are not the 1st owner then you don't know how previous owner treated bike. Often sportbikes are rode hard and banged into 2nd gear which can eventually cause tranny problems like bent shifter fork. First look down by the shifter pedal and inspect that it is fastened securely to the shift rod coming out of the engine/trans case. There is a single bolt that holds the shift lever on a splined shaft and can come loose and cause problems.
If that is ok then find a local mechanic you trust....Good Luck !