Transmission problems!
 

Well my bike is having an issue. It has 200 babied miles on it. Issue has gotten progressively worse.

When I shift from 5th to 6th the bike goes into 6th then immediately falls into neutral and back into 5th. Seemed like once it stayed in gear it would stay there.

Called Gerry, he said tighten the shift lever and change the oil with 20w50.

Did that this afternoon. Took the bike still falls out of gear and now once its in gear it will randomly fall out into 5th.

At this point its unsafe and can't be ridden.

any thoughts?

How much play do you have in your clutch cable?

check carefully with any binding of the shift lever where it passes through the engine cover.

I doubt this has anything to do with the oil.

Does it malfunction in any other gears?

I would NOT ride it until diagnosed and repaired. Flipping between neutral and gear can break something. May be OK if you stay out of sixth.

Clutch cable has the correct amount of play and doesn't bind. The gear issue is only 5th to 6th. The shift shaft rotates fine.

Contacted Gerry at CSC. He is finding out what they can do. Stay tuned.

I'll wait for others to chime in but sorry to say I suspect there is a problem.

Not many easy to inspect or repair things that can be contributing.

I think the next thing to do will be to pull the left side cover and inspect the indexing star (I don't know the proper name for it offhand) but wait for more expert opinions to filter in. If Weld or Spud don't catch this thread maybe PM them to look at it.

In the meantime if you consider it to be a five speed bike it should be safe to ride. Since I don't know what's causing the 'ghost shifting' I can't say if won't be further damaged by the 5->6->N->5 ghost shifting.

What sort of warranty does CSC have?

2 year unlimited mileage. This is a month old with only 200 miles on it. I'm waiting on CSC to call me back. Gerry mentioned sending out an entire engine assembly..

I have 4 other bikes to ride. I'll stick to the Japanese bikes.

Always good to have a stable. Doc understands...

I wonder if they ship you an engine if they expect the original back. May be a win here...

When CSC installed my new engine, they gave me the old one back. Now I have spare parts :)

just over 1000 miles and my bike has not seen 6th gear very much not too flat around here i would not ride it at all something is wrong might be unsafe

Gear logic.
 

Let's think about this.
The trans design uses forks to move sliding gears to either engage or disengage, and the power is transmitted through the engaged gears.

The shift drum is what moves the forks. A spring loaded arm holds the drum in place via the star wheel or stopping plate (http://www.cscmotorcycles.com/STOPPI...-p/z21-110.htm ) once a shift is completed. If the shift action is not fully enacted, the arm may not sit down in the detent to hold the selection, and therefore might pop up to the top of the ramp of the stopping plate, giving a false neutral. A bit more vibration and the drum moves to select the next lower gear.

If the fastener that holds the stopping plate is loose, that can cause the "short shift" action you are experiencing. A worn/defective pin in the 5-6 gear selector position can do the same thing.

There are other possibilities, including bad bushing, gear, shift fork, etc.

If it were happening to me, I would remove the right crankcase cover to be able to inspect and watch the action of the shift linkage.

Good luck.

Bummer!
 

Keep us posted, and let me know if there is anything I can do to help, being within 30 mins away!

CSC is sending a new engine complete. I'm sending the old one back as they want to find out what went wrong in the transmission. I'll pull the defect out tomorrow or Monday.