Hard downshifting into 4th gear - MVAgusta.net
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post #1 of 27 (permalink) Old 07-24-2018, 11:13 AM Thread Starter
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Question Hard downshifting into 4th gear

I tried searching the forums but couldn't find any information on this.

2006 Brutale 910S

Every time I downshift from 5th into 4th gear, I have to apply extra force to get it into gear. All the other gears shift smoothly. Clutch disengages as it should. There are no abnormal noises either, it's just hard to press the shifter down into gear. Up shifting is smooth throughout all gears as well.

I'm planning to change the oil to see if it helps any, but has anyone faced this problem before? Possibly worn out shift drum? Normal for Brutales perhaps?

Any help is appreciated.
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post #2 of 27 (permalink) Old 07-24-2018, 11:03 PM
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gmandrik;
MVs have very reliable transmissions......the usual problem is the shift lever spring breaks and
the the lever will not return to the center position
The other thing that breaks is one of the ratchet pawl springs and it will only shift up or down

You only have a problem downshifting between the same 2 gears.....
So I doubt it's the drum, my vote bent fork or problem with the shims/snap ring on 4th or 5th

Is it stiff coming out of 5th or going into 4th?

Time to pull the transmission and see what's up....Please post pictures

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post #3 of 27 (permalink) Old 07-25-2018, 08:24 AM Thread Starter
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Quote:
Originally Posted by theknurl View Post
gmandrik;

You only have a problem downshifting between the same 2 gears.....
So I doubt it's the drum, my vote bent fork or problem with the shims/snap ring on 4th or 5th

Is it stiff coming out of 5th or going into 4th?

Time to pull the transmission and see what's up....Please post pictures

I'm assuming it's stiff going out of 5th. The shift pedal doesn't do anything until you apply more force to it and then it shifts into 4th as it should.

Pulling out the transmission is what I was trying to avoid . I will need to pull out the clutch first, correct? If so, is it hard to remove without the "special tool" that holds the clutch?
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post #4 of 27 (permalink) Old 07-25-2018, 10:05 AM
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Since you only have difficulty with one gear it is definitely internal transmission. The clutch removal requires removing the central nut, which means holding the clutch hub.....or using an 1/2 inch drive air impact wrench !!!

Of course, to torque the nut on assembly the air gun won't work (unless you just hit i and "hope" you got it tight enough).

There are inexpensive tools available to do the job. I've had one like this in my tool box since the 70's:
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post #5 of 27 (permalink) Old 07-25-2018, 11:50 AM Thread Starter
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Has anyone tried the belt method? thoughts? Youtube link below.

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post #6 of 27 (permalink) Old 07-25-2018, 11:52 AM Thread Starter
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Also, I know I need to replace the clutch cover gasket after tearing into it, but what about the transmission side? Is there a gasket that needs to be removed on that side as well? I can't seem to find it on the diagrams.
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post #7 of 27 (permalink) Old 07-25-2018, 12:48 PM
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The transmission plate is inside the cases...no gasket.

The belt method can work...but it's a PIA.

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post #8 of 27 (permalink) Old 07-25-2018, 01:40 PM Thread Starter
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Is there a good DIY on transmission removal/assembly somewhere? I tried searching but couldn't find any.
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post #9 of 27 (permalink) Old 07-25-2018, 02:01 PM
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Quote:
Originally Posted by gmandrik View Post
Is there a good DIY on transmission removal/assembly somewhere? I tried searching but couldn't find any.

In the workshop manual on Donsy's site:
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post #10 of 27 (permalink) Old 07-25-2018, 02:06 PM
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Engine Manual

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