Katana shifting trouble

[cnap504]

Recently got a non running 1982 Katana 1000, it had some typical long term lay up issues but I have gotten it running and riding reliably. On upshifts if I’m very deliberate it engages the next gear, anything less than a careful upshift requires a second attempt.  All the gears are there and I’ve been through all of them.  The clutch began to give up without warning when rolling on at highway speeds so pulled the cover and inner hub to find the outer basket nut had loosened some, hand tight with the lock tab washer still in place.  All the fiber plates were broken, the clutch considering it’s condition worked a lot better than it should have,  I’m putting it back up with new fibers, new oem springs, new nut and washer, the inner and outer hubs have some grooves which I filed and sanded fairly smooth.  While this stuff is out should I check the shift shaft “pawl” and spring?  How to do this and what to look for?  Shift drum detent plunger and spring?

 Thanks 

 

 

Edited October 11, 2021 by cnap504
typo

[TonyGee]

have you checked/cleaned the gear lever pivot point ?  also pull the front sprocket cover off and make sure the shaft hole is clear. 

[cnap504]

I’ll have a look 

[Mike711]

Your broken clutch won't help but if it's still sticky when rebuilt, start with chain adjustment i.e. the easy/cheap bits & work up to gearbox bits.

[neilw]

The small spring that works on the gear shift stopper cam ( parts nos 09443-08019) , it is accessible and can be changed by dropping the sump plate, it was gone on mine when I bought the bike  in 1984  (the bike went through 3 owners in 2 years because of the gearchange and they could not fix it )

 

Sounds similar to yours , changed mine and bike has been fine since then 

[cnap504]

neilw;  the spring you referred to was missing or worn out ?  Thanks for the response 

[kochic]

usually its the spring on the shifter shaft.the shifter do not return in the middle position.You don't need to remove the pan.You will need to remove the clutch to have acess to the spring and pull the shaft out of the engine.

Marc

[neilw]

 I went through the route of taking out the clutch , swapping the gear change shaft etc etc and nothing worked, I spoke to a chap who drag raced gsx1100's who put me onto that spring.

 

I bought a new sump gasket and when I dropped the sump pan the spring was sitting in two pieces in the bottom of it, the bent section on one end that clips over a retaining boss in the bottom of the engine casings had snapped off .

 

That was in 1984 and 37 years and 50,000 miles later the replacement is still fine

[Swiss Toni]

Pip Higham used to fit two springs for a more positive action. Just saying. 

[coombehouse]

I had issues last year with the lever not returning after a shift. It was caused by excessive wear in the bearing on the shift drum. It had huge miles on it though