tearing into the tranny help

[Pat Kelly]

Can't get the #%$*@! countershaft assy. back in. It coes close, but no cigar.
I've even tried without the shift forks to see what might be holding me up (or out as the case may be).
This is getting frustrating.

[DiverRay]

Pat,
I can't get over until Sunday, but PM me if you need help with it.
Ray

[Ken Talbot]

Have you tried the reassembly secrets ?

[Pat Kelly]

I got the countershaft cluster in. What I had to do (and wasn't mentioned) was to remove the kick-start gear. Of course that would only apply to bikes (my E) that have the kickstart mechanism.
I see in the picture of the right side stripped-down the bearing cap the kick gears is there but no gears.

Now I'm wrestling with the 5th gear fork.

Sadly with my dizzyness I can't lay under the bike for too long before I have to throw-up. The world just starts whirlling in circles.

"Git 'Er Done!!!"

[Pat Kelly]

Hmmm..... kickstart gear has to be in there before the cluster shaft. Since I never use it I'm going to leave the inner gears out.

Things are going back together.

[Pat Kelly]

Well crap, broke one of the posts in the clutch. Fortunately I bought another clutch assy off Ebay several years ago. I'm going to follow an earlier thread and run bolts in from the backside to strengthen the posts. Then I will epoxy and reinforce the broken (pressure?) plate and have another back-up. The LG will need clutch attention before long, it occasionally slips under hard acceleration. I'll be installing another steel plate.

So glad I have two bikes. With it getting cooler I'd like to get behind (as someone once described)"the big, butt-ugly, Pacifico fairing". Sorry, but the sleek-looking Martini fairing dosen't protect as well.

[Pat Kelly]

I resurected the original thread but will link it HERE .

I think I'm going to reinforce all 6 posts.

[Pat Kelly]

I did reinforce all 6 posts on the unbroken pressure plate.
I installed the star plate and the bolts (no springs) then drilled and tapped the backside. I used high-strength locktite and ran the bolts in to where they butt-up against the bolts that hold on the star plate and clutch springs. Then I cut off the heads and ground the (now) studs flush. All similar to Maximans but with longer studs. Should have it wrapped-up shortly.

The Wiesco 1196 kit has arrived for the LG. All that remains for that project is $ to bore the spare cylinders I have. I may do the cam chain while I'm there.

[Pat Kelly]

It's all done and working great. While testing it a new sportbike split lanes and pulled alongside me at a stoplight. The other bike had a passenger on it. When the light changed I really wan't racing, just testing 2nd gear (as I explained to them at the next light). I walked away from him when the light turned green. I could tell he was gassing it and I hope he was going easy because he had a passenger. At the next light he said he wished 'she' wasn't on back (again, I hope it was a safety issue). I told him "Well, my bike's 25 years older, 300 lbs heavier, and I outweigh you by probably 100 lbs. We should be pretty even."
We both left that next light at a normal speed. I turned right and tested 2nd gear some more.