digging into the tranny

[TopCatGr58]

Hey Adam,

The manuals I've just looked at show only 2-3mm distance gap between the cable end of the lever and the lever holder/bracket/stopper that it pulls up against. This would probably cause about a 5mm amount of travel of the actual finger end of the clutch lever towards the handlebar. You want to have enough slack to ensure full release of the tension of the cable and the clutch throwout lever so that the clutch won't be slipping, but if you have TOO much slack, then when you go to pull it, you won't necessarily pull enough to fully disengage the clutch for proper smooth shifting as well as being able to keep the engine/bike from trying to creep forward at a complete stop.
T.C.

[adam79]

yeah, I just finished putting everything back together. I made my back cuts at too great of an angle I think, cause I am having one hell of a time shifting up to 2nd gear. I rode slow around the coltasack for a few loops, and the bike did shift through all the gears, but at higher speeds it does not come out of first. Good news though,,,,,no slip of the dogs! I am hopeful that I can 'break in' the tranny without too much trouble. The bike still wants to roll forward slightly when at a stop, so Ill have to adjust the clutch more, and maybe that might even help with the shifting.

[XSPastor]

yeah, I just finished putting everything back together. I made my back cuts at too great of an angle I think, cause I am having one hell of a time shifting up to 2nd gear. I rode slow around the coltasack for a few loops, and the bike did shift through all the gears, but at higher speeds it does not come out of first. Good news though,,,,,no slip of the dogs! I am hopeful that I can 'break in' the tranny without too much trouble. The bike still wants to roll forward slightly when at a stop, so Ill have to adjust the clutch more, and maybe that might even help with the shifting.

FWIW, mine shifted hard after the gear fix too and replacing the shift lever return spring made the problem go away. YMMV

[adam79]

FWIW, mine shifted hard after the gear fix too and replacing the shift lever return spring made the problem go away. YMMV

I did replace that spring..

I replaced the shift lever return spring (torsion spring), 6 clutch springs, and 8 friction plates with new parts, plus I tested and sanded down of all 7 steel plates.

[TopCatGr58]

Hey Adam,

First, congrats on a job completed successfully!

Secondly, yes, the prominent undercutting will KEEP the gears engaged under very small amounts of stress, so if the clutch isn't disengaging completely, that can cause it to be more difficult. But also, you'll be learning how to rev it up in 1st, but then quickly cut the throttle enough to release tension on the gears to allow them to come apart to shift OUT of 1st into 2nd and above. Yes, they will wear and round off a bit and will shift easier after a while.
T.C.

[adam79]

Thanks TC, this is the first major repair job I've done on a bike. I hope it doesnt rain tomorrow (washington), cause I am ready to break this beast in.

[DGXSER]

Glad you got it all back together Adam. Alot of work and some very tense moments went into mine, so I am sure yours was similar.

I do have to shift like I REALLY mean it up into second or it drops back to neutral. Not after it is in gear, but if I dont pull up with a purpose, it won't go in.

For now it is way to cold and nasty here for ridin, hope you get to put some miles on the beast. For now sit back, drink a cold frosty beverage and rejoice in alot of hard work well done.

[bikerphil]

Adam79, Congratulations on a job well done! I'm sure you'll notice it shifts much better after dialing in the clutch and getting used to the new shifting feel.

[adam79]

After riding around on my bike today, I am confident that the tranny is getting better and will break in the back cuts. Thanx to everyone who helped me! A lot of headaches were avoided by the advice of those who have already had them. Next on the list, the rear caliper.

btw, I remember when I first bought the bike and I went to a bike shop to get a price quote on some fixes......they said the back cut on my gears would easily come to at least $1000, not including the clutch. Thanx, but I'll pass on that.

[trbig]

We'll all be expecting our cut of the profits in the mail...


Glad it worked out.

Tod