Problems downshifting DS80

[RAKxp]

A month ago, I bought an 86 DS80 for 200 bucks for a winter project. I tore it down, replaced all the seals and piston/rings. When I split the cases, all the gears looked good as well as the shift forks. The manual was very vague when it came to info on the tranny parts but everything seemed good.

I got the bike running but I'm having problems shifting. It upshifts perfectly but is extremely hard to downshift. Sometimes you have to upshift again then try to downshift. Most the time I've had to shut the bike off and fiddle with the shifter by hand. Also, its very hard to get into first.

Any suggestions as to what to look for? I've changed the oil twice with 10w-40. Thanks for any info.

 

[RAKxp]

Could this have something to do with the shift pawl and pins. There seems to be a lot of play, like to pawl doesn't solidly grab the pins in order to turn the cam.

 

[SHSPVR]

Did you take apart the Clutch Basket Yes or No, I'm guest that you didn't then take apart the Clutch Basket there should be a big washer that need be install around a main shaft.
Secord possable it shifts folks are in wrong place backwords.

 

[RAKxp]

Thanks for the response. I double-checked the clutch parts to a diagram and everything is there. Also, I know the shift forks are in the correct location.

When I inspected the shift forks. The ears were not the same width on either side. I figured this was normal since all three were the same. I hate to have to split the cases again if this is something simple.

This is my first time ever working on bikes, especially transmissions!