New transmission and gears, issues.

deafanddiabetic · Post by **deafanddiabetic** » Wed Sep 30, 2015 7:59 pm

Hey everybody,

Ed was nice enough to set me up with new transmission shafts, and other parts. I installed them a few months ago and I was able to watch the shift drum turn and move the ears around to their appropriate places.

This may seem hard to follow and I'll add pictures tomorrow, but:

I already closed up the halves, installed the engine on the bike and started putting together the left side case with shift drum fork selector and clutch basket. Before putting this in I could turn the shift drum by hand on the left hand side and the kickstart shaft worked accordingly.

After I put the clutch basket on (I'm hoping correctly as I was using the fiche as a guide) and the selector arm, two metal arms that hold the shift drum in place by spring and small disc and the oil filter and chains, I am no longer able to turn the kickstart shaft and cannot shift the gears at all. It just seems locked in place. I did put oil in it.

I have the neutral switch installed, and there's only one way that it fits in, so I presume that that's where my neutral is supposed to be. I'm not sure if I have the shift drum arm selector in correctly or not.

When I discovered that I couldn't move the gears or kickstart shaft I pulled everything back off and took some photos. There's probably a million places I might've gone wrong, but I sent pictures to Ed when I got this transmission installed and he said it seemed put in correctly. I'd be devastated if I had to take the engine apart again because of some mishap when installing the shafts and gears.

Halp.

deafanddiabetic · Post by **deafanddiabetic** » Wed Sep 30, 2015 8:02 pm

Pictures.

This would be what I assume is "Neutral".

Hoosier Tom · Post by **Hoosier Tom** » Wed Sep 30, 2015 9:49 pm

Make sure the kick starter stopper bolt isn't binding on the kick starter spindle. You have to rotate the spindle and look through the stopper bolt hole until it is clear, then install the bolt. If you loosen the bolt and then the kick shaft turns, that was your problem. If not look at your shift drum retainer and make sure it wasn't installed upside down. I think the first thing is more likely.

HT

deafanddiabetic · Post by **deafanddiabetic** » Thu Oct 01, 2015 8:47 am

What is the kick start stopper bolt? Are you able to circle it in the image above?

Hoosier Tom · Post by **Hoosier Tom** » Thu Oct 01, 2015 2:27 pm

http://images.cmsnl.com/img/partslists/ ... 7_b5b4.gif

Part #21.

HT

deafanddiabetic · Post by **deafanddiabetic** » Thu Oct 01, 2015 10:16 pm

That was exactly it.

Took me a little bit to figure out what the "hole in the shaft" meant but I finally noticed the little ridge spinning around and an open space.

Got the cover put back on and buttoned up and it shifts beautifully.

Thanks Tom!

Hoosier Tom · Post by **Hoosier Tom** » Fri Oct 02, 2015 8:30 am

You're welcome.

HT