Gear shift stuck

ST1

Joined
Oct 20, 2024
Messages
21
Age
50
Location
UK
Bike
ST 1300
I have a 2008 A6 ST 1300.
The problem i have is, the bike shifts from first to second gear and will not shift from second into third.

This happened last weekend as the bike is only used on weekends, after about three miles riding the bike shifts normally.

Earlier today i remove the lower left hand cowling to try to lubricate the socket joints from the foot change.
On the test run after the same problem is occurring.

Any ideas what is causing this?
 
It sounds lie the shifter pawl is not returning to center.

You probably should start with lubing the two joints in the shift linkage.
 
Yes i tried lubricating the two joints earlier with some WD40. Do you mean part 3 and 4 Below.
1742061166980.png
 
sits outside? Take it apart clean and lube with some fresh grease. The 99.5% of shifter problems.
 
I have taken another look and there are two rubber pipes, (Drain pipes?).on top of the clutch slave cylinder and part 12 on the above diagram.
There are witness marks to the one pipe, i have moved these over slightly around the clutch slave cylinder.
the gear shift lever appears to be unjammed. Will test ride tomorrow.1000005781.jpg1000005782.jpg1000005785.jpg1000005786.jpg
 
Since you are working on the bike, when was the last time you changed the clutch hydraulic fluid (brake fluid)? It should be changed every two years.
 
SMSW said:
Since you are working on the bike, when was the last time you changed the clutch hydraulic fluid (brake fluid)? It should be changed every two years.
Click to expand...
About eighteen months ago, good advice.
 
You probably have two issues going on.
1. Your clutch slave cylinder gave up the ghost (see witness stains on back of crankcase cover)
2. Your clutch lever brass bushing is probably damaged and worn excessively not giving you a complete throw.
I would start by removing/replacing the clutch slave cylinder, flushing the system out, bleeding the air out, and then replace the clutch master cylinder bushing/boot.
 
I’ve seen this problem caused by a stone getting caught in the linkage as well. Looks like those hoses were misrouted. Good catch.
 
When I see these pictures, the dirt and grime, I'm not surprised that nothing's working anymore.
holm
 
Hi Igofar do mean part 3 for the clutch lever brass bushing. The bike has covered 29000 miles.
1742067800556.png
 
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Hold part #21 with a large flat screwdriver, then use a 10mm wrench to remove the lower fastener, then remove part #21.
Remove the brass bushing #3 and inspect it.
You may find the rubber boot #12 will be torn.
If the boot is torn, grasp the end of the pushrod #2 and pull it out.
Does it appear that there is an O-ring around the center of it? There is not, this would be the end of the torn boot.
Does the brass bushing appear scored or damaged?
Does the lever have excessive up and down movement? The other brass bushing worn.
Did the pushrod #2 wear into the bushing too deep? This will not allow you to move the clutch plates enough, causing difficulty shifting.
My money is on your failed clutch slave cylinder, and a failed bushing.
Take some pictures of the bushing and rod and post them for us to verify if there is damage or not.
 
Igofar said:
Hold part #21 with a large flat screwdriver, then use a 10mm wrench to remove the lower fastener, then remove part #21.
Remove the brass bushing #3 and inspect it.
You may find the rubber boot #12 will be torn.
If the boot is torn, grasp the end of the pushrod #2 and pull it out.
Does it appear that there is an O-ring around the center of it? There is not, this would be the end of the torn boot.
Does the brass bushing appear scored or damaged?
Does the lever have excessive up and down movement? The other brass bushing worn.
Did the pushrod #2 wear into the bushing too deep? This will not allow you to move the clutch plates enough, causing difficulty shifting.
My money is on your failed clutch slave cylinder, and a failed bushing.
Take some pictures of the bushing and rod and post them for us to verify if there is damage or not.
Click to expand...
I removed the clutch lever earlier.
Not sure about the o ring.
20250323_171351.jpg20250323_171414.jpg20250323_171433.jpg20250323_171456 - Copy.jpg20250323_171456.jpg20250323_171501.jpg
 
There is NO O-ring, what you are seeing on the push rod is the torn/damaged end of the boot.
Take a picture of the lever from this angle so I can see if the rod was boring into the lever, which would cause all your issues if the rod went clear through the bushing.
Even if it didn’t, it could have deepened the hole causing your issues.
 

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The boot (45504410003) is £12.66 ~ Dave Silver.
I replaced the "Piston Master Set: 22886MCSG01"
£38.40 from Dave Silver.
 
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Have you replaced the bushing, part number #3?
If the hole was worn deeper, this could cause your issues.
 
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