Planet Minis

ducatilover · 09-09-2008, 04:08 AM

So I started working on my Z @ 10pm and @ 3am ran into a road block while installing my manual clutch conversion. Maybe you can help with the problem so I can get some sleep.

I just installed (well partially) a BrandX manual clutch conversion for my K4. I got the new shift shaft in but noticed the clutch only shifts from neutral to 1st gear. It shifts into 2nd every now and then but it usually will not go past second gear. Its seems like the thingie below does not spin all the way preventing the hook on the shaft to hook onto the next lobe. Has anyone ran into this problem? I tried putting the oem shaft back on and Im still getting the same problem. Any ideas on how to fix the issue? I searched the whole pm forum and found one other person having the same problem but no one reported a fix. Here is the person's description. Im having the same issue.

Quote:

Originally Posted by realgraverobber

Installed my eBay (Brand X Minis) manual clutch kit, and I have the following issues/questions:

-When I upshift or downshify, the shifter sticks in the upswing or downswing, unless I touch it a tiny bit with my foot. It is not returning like it did as a stocker. Does this stop happening after the shifter is gets broken in more? The new shifter Brand X sent me with their kit looks a little craggy and not as nice and straight as the Factory Honda one. Any experience with this change?

BlackBeard · 09-09-2008, 10:12 AM

you should be fine, sometimes you need the gears turning to continue shifting, my brand-x kit has been flawless in my crf. make sure when you install that shift shaft that the two spring ends go on either side of t he post on the engine case.

arlindsay1992 · 09-09-2008, 11:16 AM

Did you test with the motor running? The tranny needs to be spinning to work unless you are in that magic spot when all the gears are aligned and can shift without spinning. If there is still a problem when running it sounds like one of the springs is loose. Maybe the detent arm spring or one of the two on the shift shaft.

boonacka · 09-09-2008, 11:19 AM

spin the wheel whil ein gear on the stand a bit and it should click in

ducatilover · 09-09-2008, 11:19 AM

Quote:

Originally Posted by arlindsay1992

Did you test with the motor running? The tranny needs to be spinning to work unless you are in that magic spot when all the gears are aligned and can shift without spinning. If there is still a problem when running it sounds like one of the springs is loose. Maybe the detent arm spring or one of the two on the shift shaft.

Havent tested it yet. I was hesitant to put it back together fearing Ill have to take it apart again if the problem was still there. Ill have to give it a try. Has anyone used the stock shift shaft and just cut it down?

arlindsay1992 · 09-09-2008, 04:01 PM

Quote:

Originally Posted by ducatilover

Havent tested it yet. I was hesitant to put it back together fearing Ill have to take it apart again if the problem was still there. Ill have to give it a try. Has anyone used the stock shift shaft and just cut it down?

I have not done this myself but after comparison of the TB manual clutch shift shaft and an OEM one, I am positive that it would work fine. I would not hesitate using a cut OEM shaft if I didn't have a pre cut shaft. Be careful though, if it is too long it will hold the clutch cover off the case and the motor will leak oil it will also bind. If it is too short, you might have problems with the ratchet arm not lining up with the pins in the shift drum. You have a 1-2mm margin for error.

thorwarrior915 · 09-09-2008, 04:22 PM

I am running a cut down honda auto shift shaft with my BXM clutch kit. arlindsay is right about cutting it down. I hadn't cut enough off the first time, and the shaft was bound up when i tightened the cover down. Compare the auto shaft to the manual shaft and you will see how much you need to take off.

I dont remember exactly what was wrong with the BXM shift shaft... but it just wasn't near the quality of a honda one. The return spring that goes on either side of that post on the case was thinner and weak, and the "pawl" that catches the pegs on the shift drum was not shaped as precise as the honda unit. I put the honda one in and haven't looked back.

ducatilover · 09-09-2008, 06:55 PM

Quote:

Originally Posted by thorwarrior915

I am running a cut down honda auto shift shaft with my BXM clutch kit. arlindsay is right about cutting it down. I hadn't cut enough off the first time, and the shaft was bound up when i tightened the cover down. Compare the auto shaft to the manual shaft and you will see how much you need to take off.

I dont remember exactly what was wrong with the BXM shift shaft... but it just wasn't near the quality of a honda one. The return spring that goes on either side of that post on the case was thinner and weak, and the "pawl" that catches the pegs on the shift drum was not shaped as precise as the honda unit. I put the honda one in and haven't looked back.

I do agree that the spring and the "pawl" are not as good as oem but I kind of expected that. I did reuse the stock return spring. I put some thread lock on the bolts and left them snug but Im still having the same issue. I tried rolling the bike while in gear and had no luck.

ducatilover · 09-16-2008, 08:40 PM

Well I finished installing the kit today and am still having the problem shifting past 1st gear. I haven't started the motor yet but noticed the shifting problem was still there. Any more suggestions?

The install went ok. The quality is acceptable and there is a clearance issue with the clutch cable and the stock exhaust.

arlindsay1992 · 09-17-2008, 04:55 AM

It needs to be spinning to shift. START THE BIKE!!!

vegatron75 · 09-17-2008, 06:00 AM

I did the brand x clutch kit. I had big problems shifting the bike w/ the supplied shift shaft.
I eventually cut the the stock shaft down and used it instead.

ducatilover · 09-22-2008, 02:53 PM

So I started the bike and crossed my fingers. No luck. I still cant shift past 1st gear. Clutch is adjusted and bike runs fine but I cant seems to shift past 1st. Any other suggestions?

arlindsay1992 · 09-22-2008, 03:03 PM

Did the shifting work before you did the clutch conversion?

ducatilover · 09-22-2008, 03:04 PM

Quote:

Originally Posted by arlindsay1992

Did the shifting work before you did the clutch conversion?

Shifted just fine on the auto clutch.

arlindsay1992 · 09-22-2008, 03:04 PM

Are you using the BXM shift shaft?

ducatilover · 09-22-2008, 03:06 PM

Quote:

Originally Posted by arlindsay1992

Are you using the BXM shift shaft?

Not sure what that is but Im using the one that came with the kit.

arlindsay1992 · 09-22-2008, 03:08 PM

BXM=Brand X Minis

I'd cut down the Honda shaft at this point.

ducatilover · 09-22-2008, 03:09 PM

Quote:

Originally Posted by arlindsay1992

BXM=Brand X Minis

I'd cut down the Honda shaft at this point.

Thats what I was fearing I would have to do.

dirtbkr188 · 09-22-2008, 03:22 PM

Try swapping the Honda actuating arm and spring onto the BXM shift shaft, and see if that works for you.

ducatilover · 09-22-2008, 04:01 PM

Quote:

Originally Posted by dirtbkr188

Try swapping the Honda actuating arm and spring onto the BXM shift shaft, and see if that works for you.

Went into chat but you're not there. Im when you are available.

09-09-2008, 10:12 AM	#2 (permalink)
BlackBeard "ZBBT" Join Date: Oct 2007 Location: 50 riders Posts: 1,836 My Mood:	Re: BrandX clutch conversion help you should be fine, sometimes you need the gears turning to continue shifting, my brand-x kit has been flawless in my crf. make sure when you install that shift shaft that the two spring ends go on either side of t he post on the engine case.

09-09-2008, 11:16 AM	#3 (permalink)
arlindsay1992 "High Speed Record Guy" Join Date: Mar 2006 Location: Northern Virginia Posts: 4,369	Re: BrandX clutch conversion help Did you test with the motor running? The tranny needs to be spinning to work unless you are in that magic spot when all the gears are aligned and can shift without spinning. If there is still a problem when running it sounds like one of the springs is loose. Maybe the detent arm spring or one of the two on the shift shaft.

09-09-2008, 11:19 AM	#4 (permalink)
boonacka 3rd Gear Member Join Date: Mar 2006 Location: SolomonRacing.net Posts: 1,191 My Mood:	Re: BrandX clutch conversion help spin the wheel whil ein gear on the stand a bit and it should click in

09-09-2008, 04:22 PM	#7 (permalink)
thorwarrior915 3rd Gear Member Join Date: Dec 2003 Location: Malone, NY Posts: 4,549 My Mood:	Re: BrandX clutch conversion help I am running a cut down honda auto shift shaft with my BXM clutch kit. arlindsay is right about cutting it down. I hadn't cut enough off the first time, and the shaft was bound up when i tightened the cover down. Compare the auto shaft to the manual shaft and you will see how much you need to take off. I dont remember exactly what was wrong with the BXM shift shaft... but it just wasn't near the quality of a honda one. The return spring that goes on either side of that post on the case was thinner and weak, and the "pawl" that catches the pegs on the shift drum was not shaped as precise as the honda unit. I put the honda one in and haven't looked back.

09-16-2008, 08:40 PM	#9 (permalink)
ducatilover 2nd Gear Member Join Date: May 2008 Location: Peoria, AZ Posts: 622 My Mood:	Re: BrandX clutch conversion help Well I finished installing the kit today and am still having the problem shifting past 1st gear. I haven't started the motor yet but noticed the shifting problem was still there. Any more suggestions? The install went ok. The quality is acceptable and there is a clearance issue with the clutch cable and the stock exhaust.

09-17-2008, 04:55 AM	#10 (permalink)
arlindsay1992 "High Speed Record Guy" Join Date: Mar 2006 Location: Northern Virginia Posts: 4,369	Re: BrandX clutch conversion help It needs to be spinning to shift. START THE BIKE!!!

09-17-2008, 06:00 AM	#11 (permalink)
vegatron75 2nd Gear Member Join Date: Jul 2006 Location: South of Kansas City Posts: 637	Re: BrandX clutch conversion help I did the brand x clutch kit. I had big problems shifting the bike w/ the supplied shift shaft. I eventually cut the the stock shaft down and used it instead.

09-22-2008, 02:53 PM	#12 (permalink)
ducatilover 2nd Gear Member Join Date: May 2008 Location: Peoria, AZ Posts: 622 My Mood:	Re: BrandX clutch conversion help So I started the bike and crossed my fingers. No luck. I still cant shift past 1st gear. Clutch is adjusted and bike runs fine but I cant seems to shift past 1st. Any other suggestions?

09-22-2008, 03:03 PM	#13 (permalink)
arlindsay1992 "High Speed Record Guy" Join Date: Mar 2006 Location: Northern Virginia Posts: 4,369	Re: BrandX clutch conversion help Did the shifting work before you did the clutch conversion?

09-22-2008, 03:04 PM	#15 (permalink)
arlindsay1992 "High Speed Record Guy" Join Date: Mar 2006 Location: Northern Virginia Posts: 4,369	Re: BrandX clutch conversion help Are you using the BXM shift shaft?

09-22-2008, 03:08 PM	#17 (permalink)
arlindsay1992 "High Speed Record Guy" Join Date: Mar 2006 Location: Northern Virginia Posts: 4,369	Re: BrandX clutch conversion help BXM=Brand X Minis I'd cut down the Honda shaft at this point.

09-22-2008, 03:22 PM	#19 (permalink)
dirtbkr188 3rd Gear Member Join Date: May 2004 Location: New Jersey Posts: 2,972	Re: BrandX clutch conversion help Try swapping the Honda actuating arm and spring onto the BXM shift shaft, and see if that works for you.

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