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  #1 (permalink)  
Old 08-10-2006, 06:49 PM
Pro Rider
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Default Z400 Shifting Problem

After yesterday's ride in the Dunes, I figured out that my son's Z400 isn't shifting properly. Going from 1st to 2nd, it usually just finds Neutral instead. You have to play with it to get it to finally shift into 2nd. 2nd thru 5th (& reverse) all work fine. We rode it all day at the dunes only using 2nd thru 5th and everyting was great.

Can any of you Mechanic Gurus offer a novice like me a clue on what to look for?

I'm thinking maybe a bent shift fork or something like that. Looks like it is time to split the case...
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Old 08-10-2006, 07:01 PM
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Default Z400 Shifting Problem

THATS WHAT HAVEN 2 MY FRIENDS BIKE BUT 4TH GEAR
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Old 08-10-2006, 08:22 PM
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Default Z400 Shifting Problem

dude change ur oil and set ur clutch
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Old 08-10-2006, 10:03 PM
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Default Z400 Shifting Problem

Not an oil problem. My son indicated it started doing it a couple rides ago. It's already got fresh oil in it.

Not a clutch problem. The clutch works great and is adjusted properly. Clutch releases fully for shifting and doesn't slip at all when engaged.

It’s a tranny problem. Something in the tranny is not transferring the gear properly, preventing it from getting past neutral into 2nd gear.

Please only comment if you are a mechanic or who have experienced this problem and fixed it. This is not a maintenance issue.
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Old 08-10-2006, 10:38 PM
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Default Z400 Shifting Problem

I've had some problems with real notchy, hard shifting when it's running hot. I have an 06, I sent it in for the clutch cover recall. I had it checked prior, and they said it looked fine. They didn't fill the coolant all the way up when they changed the cover, so I pulled the plug to fill the overflow resivoir to the full mark. I found corroded aluminum all over the ribs on the plug.
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Old 08-10-2006, 10:56 PM
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Default Z400 Shifting Problem

you might have a worn thrust washer holding the gear in place or possible loose bushing on the gear
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Old 08-11-2006, 12:59 AM
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Default Z400 Shifting Problem

Mine gets wierd out in the sand as well.


I just figure it doesnt like the dunes.. *looks around*

[img]i/expressions/face-icon-small-shocked.gif[/img]
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Old 08-11-2006, 09:56 PM
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Default Z400 Shifting Problem

I know what you mean. i'm always missing the shift into 2nd at the dunes, its like i'm cursed out there
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Old 08-17-2006, 08:21 PM
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Default Z400 Shifting Problem

I have an '06 and it sometimes does the same thing. About the clutch cover recall: How can you tell if they switched it out or not? Are there any identifying marks?
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Old 08-17-2006, 09:06 PM
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Default Z400 Shifting Problem

the new one is aluminum.
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Old 08-17-2006, 09:06 PM
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Tags
2006, 400, clutch, fork, gears, hard, hot, ltz, ltz400, missing, problem, problems, shift, shifting, suzuki, z400



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