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

Discussion in 'Technical Help' started by Gregor, Oct 21, 2020.

  1. Gregor

    Gregor New Member

    Mar 26, 2016
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    #1 Gregor, Oct 21, 2020
    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

    [​IMG]
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    VIDEOS
    https://www.youtube.com/playlist?list=PLtZKDSDKpxEsWz1y03UKRS-QwqKPT2vqP
     
  2. Callumity

    Callumity Elite Member

    Feb 25, 2017
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    #2 Callumity, Oct 21, 2020
    Not certain because of low video resolution but is the bearing on the cam follower entirely healthy?
     
  3. Gregor

    Gregor New Member

    Mar 26, 2016
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    #3 Gregor, Oct 21, 2020
    Try to adjust the video settings, they are all HD. Not sure which bearing you mean, is this one?

    Screenshot 2020-10-21 at 13.05.45.png
     
  4. Callumity

    Callumity Elite Member

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    #4 Callumity, Oct 21, 2020
    No. I am talking about the wheel on the detent arm that rides on the irregular star shaped detent wheel. Excessive slack there would not create sufficient movement in the selector drum.
    I am not saying there IS a problem just that I cannot be certain from the picture.
     
  5. Gregor

    Gregor New Member

    Mar 26, 2016
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    #5 Gregor, Oct 21, 2020
    The wheel has a bit of slack but not sure if is too much, the whole arm moves back and forth a-lot, you can see that in the video number 9.
     
  6. Ducatitotriumph

    Ducatitotriumph Crème de la Crème

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    #6 Ducatitotriumph, Oct 21, 2020
    It all looks ok there to me in the videos (except where it stops/has issues. i'm no specialist at all) so maybe the selector forks (in the gearbox) are having issues?
     
  7. Callumity

    Callumity Elite Member

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    #7 Callumity, Oct 21, 2020
    Couple of questions (ok three!)

    Have you checked all the clutch plates on a piece of glass for any war page?

    What brand and grade of oil have you been using?

    Have you checked the oil for metal particles with a magnet? You can re-use it if all well.
     
  8. Gregor

    Gregor New Member

    Mar 26, 2016
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    #8 Gregor, Oct 21, 2020
    Selector forks was my next guess, but hoping is something else...
     
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  9. Gregor

    Gregor New Member

    Mar 26, 2016
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    #9 Gregor, Oct 21, 2020
    Didn't check the plates with glass, will do next. Oil is Castrol Power 1 Racing 4T 10W-40 and been using that for years. Oil was clean and still honey dark colour..
     
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  10. Callumity

    Callumity Elite Member

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    #10 Callumity, Oct 21, 2020
    Well all the observable stuff suggests you either have an internal selector problem (possible but unlikely) or clutch drag inhibiting selection.
    Plainly you are using the right oil so, if the plates are flat, the question comes back to adjustment. Don’t want to insult your intelligence or ‘teach Granny’ but do you have minimal slack at the lever before it takes up resistance? If you don’t/didn’t then you might have had unobserved clutch slip that overheated the plates. Too much and you can’t free off the clutch enough to cure drag..... and a new cable WILL stretch a bit and may need re-adjustment.
    In short, I would rule out clutch issues before further disassembly.
     
  11. Gregor

    Gregor New Member

    Mar 26, 2016
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    #11 Gregor, Oct 21, 2020
    You are not insulting at all every hint can help. That was the first thing that I checked, slack 2-3m as per manual, lever is further out as possible I think is on 1. Same with the new cable I have adjusted the cable after a short ride, but same issues.
     
  12. Ducatitotriumph

    Ducatitotriumph Crème de la Crème

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    #12 Ducatitotriumph, Oct 21, 2020
    Didn't it still also get stuck with no clutch on the bike? (in the videos)
     
  13. Gregor

    Gregor New Member

    Mar 26, 2016
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    #13 Gregor, Oct 21, 2020
    Last edited: Oct 21, 2020
    Yeah same problem, you can't get all the way up or down without being stuck somewhere...
     
  14. Callumity

    Callumity Elite Member

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    #14 Callumity, Oct 21, 2020
    I didn’t notice any issues but that is the key test. If you cannot run up and down the gears by manually rotating the detent wheel you have a problem in the selector drum or with the forks.
     
  15. Gregor

    Gregor New Member

    Mar 26, 2016
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    #15 Gregor, Oct 21, 2020
    Done this test in video 8 and 10, but it seems to be and internal problem then...
     
  16. Callumity

    Callumity Elite Member

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    #16 Callumity, Oct 21, 2020
    Is that Pivot Plate (T1194900?) doing its job or failing to catch when going down the gears?
     
  17. Gregor

    Gregor New Member

    Mar 26, 2016
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    #17 Gregor, Oct 21, 2020
    Not catching all the time. But since is moving also back and forth I thought that might be normal. There's also some signs of wear on it. Changing gear by turning the detent wheel you still don't go up or down without being stuck.

    IMG_1145.jpg
     
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