Help with MadMax...Calling all Gurus'

[madmax-im]

Yesterday I went to start Max up after reassembly and he wouldn't fire....not much gas in tank...today i get some gas into the tank and again cranked the starter no fire...then I decided to try the side stand up and tried starting it again...sure enough he fired right up..Yay...short lived....running really high idle with no choke...adjusted the idle down to acceptable levels...took a while for the carbs to smooth out but eventually they did..ok engine sounds good lets see how we did with the tranny...gave it some gas let out the clutch and off we go...went to shift into 2nd and nothing gear shifter moved to the 2nd gear notch but no 2nd gear...same as neutral...ok try shifting to 3rd...got 3rd gear ...shift to 4th ..ok got that too...shift into 5th..nothing...so 2nd and 5th are a no go....so WTF did we do wrong here???

[randy]

****!

I don't know, we put the same gears in the same places on the shaft! The only thing we did otherwise was move the washer.

WTF, Ben, are the carbs at least working OK? This is humiliating.

[79XS11F]

If the cases were split did you make sure the trany was in the right gear for reassembly and make sure the middle fork engaged its gear properly?
Rob

[madmax-im]

Randy carbs are running ok engine sounds good too... throttle response is crisper than before and launching from first gear was not a 3500-4000 RPM exercise...so it would appear the carbs are ok..as to the transmission it looks like I gotta do it again All I can say is ...if I dis-assemble this bike again I would like to do a complete re-wiring as this stuff is getting pretty funky....

[madmax-im]

Originally posted by 79XS11F
If the cases were split did you make sure the trany was in the right gear for reassembly and make sure the middle fork engaged its gear properly?
Rob

79XS11F...cases were not split...

[bikerphil]

shift fork

Sounds to me like one of your shift forks isn't in right. I just put my 79F tranny back together today and those forks aren't easy to get back in. Good luck!

[BLUEJEEPLAB]

I would agree with bikerphil, shift forks are a likely culprit. I did my second gear fix from the bottom through the Crank case and it was a bear. It took several attempts to get it right. When you get it back together, do a static shift through before you close up the case. I did it and it showed me that I did get it right. You may have to manually rotate the rear wheel to get it to shift, but I was able to get through all five gears before I sealed her up.

There are lots of good pictures and advice on the Tranny threads here on the site. I also used my digital camera to document stuff as I took it apart.

[madmax-im]

XSively depressed

Damn ...it took us a long time to get the dogs and forks repositioned...we pretty much thought we had it...its not like we skipped something we were there..we saw what we thought we were supposed to see,so I guess it is entirely possible that the shift fork is not where its supposed to be...I dont see any other way but to tear him down and do it again... Well at least i have a better understanding of what to do and how to do it.The only thing I dont have are alot of tools...looks like its time for a big expenditure.... When you consider that i am a turn key type of person...trying to learn to do it myself(with help and lots of it)is making me wish I just took it to the guy out in OK

[motoman]

Hey there madmax..............sorry to hear bout it not shifting right. I'll give you a little clue, even tho most hear would'nt agree..............put that bike up on some blocks on the stand so it's a bit higher off the ground...............don't flip it upside-down......repeat: don't flip it upside-down. Let gravity be your helper. When putting shaft assembly back in, first start shift fork shaft through. Holding No.3 fork in correct position, push it above so the curved fork area will ride on top of shaft. Don't slide shaft any farther than it takes to hold fork out of way! Now put shaft/gear assembly in. It's a close fit, so just jiggle it a bit as you slide it's shaft into bearing on the clutch side. It will now stay in place by itself. Pull the fork shaft back a bit and No.3 fork will almost drop in place by itself! Slide shaft on across and through No.2 fork. Before sliding shaft across any farther, put fork No.1 in its correct direction, holding it above where it goes. Take the other hand and slide fifth gear back on shaft. Let fork come down enough to slide shaft through it and on across through hole in case. I messed with mine for quite a bit, then studied the situation and when I re-approached the situation using this series of steps, it was child's play and way easy. Like I said, using gravity as a helper made it easy. Laying on a piece of carpet on garage floor on my back was only complaint. Every slot and ear got a serious matching angle when ground.

[randy]

we had a hell of a time with those forks, but it appeared to me that the forks can only be installed one way. Am I reading here that the forks can be installed upside-down, and still engage the drum?? That's f-ed up! That's the only reason I can think of that would cause this problem.

[madmax-im]

anybody wanna a bike cheap?

Well thats just abt how I feel..abt tearing it down again .something tells me its gonna be a while before I do a repeat performance.

[randy]

Ben, don't jump to any conclusions or make any rash deisions until we hear from someone that has experienced this. Besides, it will only take a couple of hours for us to open and close. I'm sure the solution is a simple one.

[DiverRay]

Ben,
Before you go and do something rash, try the simple things.....
Start with the shifter side cover, remove it, put the shifter back on the shaft and WATCH as you shift the gears. You DID line up the marks in second gear, right??
All the pins are in, and the drum seems to work correctly? If so, then you will be going in deeper.
The second time IS faster, so that will help a little. DO check the sifting BEFORE you put the covers on. I usually check before the clutch basket is in, just to keep it easy and simple.( Simple minds and all )
With Randy's help, it should only be an afternoon fix.

[randy]

With Randy's help, it should only be an afternoon fix.

HA!

I'm the one who botch it in the first place! And that was without any beers. Oh, maybe THAT's what I did wrong? No beer.

Seriously, does anyone know if the shift forks can be installed upside down?

This is humiliating.

[bikerphil]

shift fork

I think it might be possible to install the #1 shift fork upside down. The peg that fits into the shift drum is probably pointing in the wrong direction, thus, 2nd & 5th, no shifty. Not 100% sure of this but it seems to make sense. Good luck!