So after fixing the the shift shaft problem and the starter problem, the Spyder ran great for a short time. It has now developed a new shifting problem. It won't shift at all. It is stuck in 3rd gear. It will not even go into Neutral upon shut down and restart. I found an independent shop that will work on it, but he has not found the problem yet. He has determined it is not the left hand module. It is not the shift lever sliding on the shaft as before, this is new. Any thoughts I can pass along to Rusty the mechanic?
Geez. Knowing the nature of your past work, I have an ill feeling. But first, you know the drill. The first thing to check when an SE5 doesn't shift is oil level in the tank. Plus, I trust that you have verified it is ACTUALLY in gear and this isn't an indication problem. Easy enough to do. Start it up, give it some throttle and see if it tries to move.
So, the left hand switch sends an electronic shift command signal to the HCM via the TCM. It is processed into a hydraulic signal and moves the shift rod back and forth, moving that pesky shift arm back and forth to shift the gearbox. An automatic downshift signal originates in the Transmission Control Module (TCM), independent of the left hand switch, to do the same thing. A quick Go/No Go check. Have Rusty get down on the floor on the left side and watch the shift rod and the shift arm. You put your foot on the brake and start up the machine. If the shift rod and the shift arm moves normally, meaning the the HCM is trying to shift to neutral - I believe it tries 3 times - then the problem may lie at the other end of the shaft that you just replaced. Sorry. If it doesn't try to shift at all, then the issue is localized to the TCM and HCM area. Maybe an oil filter collapsed or installed backwards, or other failure. Check fuses and codes.
Back to Mikey's thought. If you guys see that the HCM is trying to shift it normally, but the gearbox isn't shifting, then get your 13mm wrench. Put it on the back side of the shifter arm where the wrench flats are. Bet you forgot about that trick. Use the wrench and try to shift the gearbox with the wrench. Pretend the wrench is a foot shifter. That’s what you’re doing. Upshift and down shift. You may have to rock the machine back a forth a bit, and disconnect the rod if you want. Don't do it with the engine running, but you can have the key on. If the gearbox still won't shift with the wrench, and you'll be able to feel and hear it sound like a regular motorcycle gearbox or not, then I'm afraid you're tearing apart the other side again, to look at the shift pawl and the index star wheel to find out why the shift drum isn't turning.
Is this enough homework for you? Actually, it won’t take but a few minutes. Keep us posted.
