2011 Diavel - frozen gear lever

[Her_C4]

2011 Diavel - went for a ride this morning, changed down into 1st to turn into a street but it didn't go into gear it hit neutral and now it's frozen. Tried heaps of things to get it into gear but nothing has worked.

Anyone got any idea what the problem might be?

Anyone in Christchurch able to llook at it sooner than the three weeks needed for Casbolts??

[awayatc]

Does gearlever itself still move up and down?
ie, is lever still connectect to shaft, or has linkage sonehow cone undone?
when you move the gearlever, ultimately (no doubt through a few linkages) it is supposed to turn a shaft in gearbox....
can you try and see if it still does that?

[Katman]

I know the picture is of a 600 Monster gear selector but the Diavel arrangement is almost identical.



My guess would be a broken spring (number 20).

[Her_C4]

Does gearlever itself still move up and down?
ie, is lever still connectect to shaft, or has linkage sonehow cone undone?
when you move the gearlever, ultimately (no doubt through a few linkages) it is supposed to turn a shaft in gearbox....
can you try and see if it still does that?

Hi

No movement at all - not even a hint of movement, it's like it is firmly frozen and everything looks as it should - no contact between the gear lever and rod. If post a pic but I damned if I know how to that via this app on my phone.

[Her_C4]

I know the picture is of a 600 Monster gear selector but the Diavel arrangement is almost identical.



My guess would be a broken spring (number 20).

Thanks - without getting into the guts of the bike right now would a broken spring cause the gear lever to be rigid /frozen? No amount of pressure will move it even a margin.

[Katman]

Hi

No movement at all - not even a hint of movement, it's like it is firmly frozen and everything looks as it should - no contact between the gear lever and rod. If post a pic but I damned if I know how to that via this app on my phone.

Then it's possible that the arm (part #24) has jammed due to the spring being broken.

[Her_C4]

Then it's possible that the arm (part #24) has jammed due to the spring being broken.

Good stuff - thanks .

[nodrog:Me]

if the lever is stiff its the shift fork (24) stuck on one on the pins(17) on the shift drum (18). If the lever is loose it means the timing gear has chewed the spring (20) and broken it.

theres a repair kit availiable with updated bolts (28,30), and a meatl plate to apply the pressure over more area to stop the whole mechanism moving and causing this problem.

I have the part number around here somewhere but it is easy to google. its around $50 I think.

Its piss easy to fix, about an hour. If you are tight you don't even have to drain the oil.

[Her_C4]

if the lever is stiff its the shift fork (24) stuck on one on the pins(17) on the shift drum (18). If the lever is loose it means the timing gear has chewed the spring (20) and broken it.

theres a repair kit availiable with updated bolts (28,30), and a meatl plate to apply the pressure over more area to stop the whole mechanism moving and causing this problem.

I have the part number around here somewhere but it is easy to google. its around $50 I think.

Its piss easy to fix, about an hour. If you are tight you don't even have to drain the oil.

Thanks - lever definitely not loose. No movement at all. Thanks I'll look it up.

[Katman]

If the lever is loose it means the timing gear has chewed the spring (20) and broken it.

Close.

It's the spring (27) that stops the gear lever flopping around like a cock in a sock.

[nodrog:Me]

Close.

It's the spring (27) that stops the gear lever flopping around like a cock in a sock.

no, what happens is when the whole mechanism moves down (or forward), the round bit on spring 20 which goes on the pin on 26 touches the timing gear (theres only 2mm clearance on a down shift when adjusted properly) and theres no tension on the shift fork 24.

trust me, I had to ride back form okororie in 5th gear the other week.

[Katman]

no, what happens is when the whole mechanism moves down (or forward), the round bit on spring 20 which goes on the pin on 26 touches the timing gear (theres only 2mm clearance on a down shift when adjusted properly) and theres no tension on the shift fork 24.

trust me, I had to ride back form okororie in 5th gear the other week.

Don't make me come over there and beat you off.

It's the spring (27) that holds the gear lever firm and provides the pressure to return it to it's the central position.

[nodrog:Me]

Thanks - lever definitely not loose. No movement at all. Thanks I'll look it up.

mine used to get stuck on every ride at least once, I used to be able to kick it and free it up. I had the parts all ready to go, but I was always going to "do it next time it happened".

then the spring went

[nodrog:Me]

Don't make me come over there and beat you off.

It's the spring (27) that holds the gear lever firm and provides the pressure to return it to it's the central position.

correct numb nuts, but spring 20 puts tension on the fork so it actually engages with the pins on the drum, instead of just rubbing them up.

feel free to come over I've still got pieces of broken spring you can molest.

[nodrog:Me]

pictures and stuff