5th gear blues revisited

[ozlad]

After going for a ride and discovering I no longer had 5th gear I went to the technical section and found the 5th gear blues. Very helpful as I discovered the dowell was missing.... luck would have it I have a spare motor that came with the bike, replaced the dowell and fixed the finger but still can't get 5th... it looks like the lever won't engage the dowell...... anyone got any ideas it would be greatly app.

[TopCatGr58]

Hey Ozlad,

Hopefully you still have the shift cover off. Did you just rebend the plate where the 5th gear dowel came out?? That plate is not very strong, and once bent, tends to bend again, so it's recommended to replace it with one that's never been bent, either from your partzer, or new OEM.

Now, the shift pawl has a synchronization/alignment setting that you can check. Shift it into 2nd gear, then release the shifter. Look at the shift pawl and the shift drum. You should see a little thin line etched into the side of each, and they should line up. IF they are not aligned, then you can adjust the shift lever so that it will be moved to put the shift pawl arm in proper alignment, and that might be what's keeping it from being able to slide far enough to grab the 5th gear dowel.

Did you figure this out by putting it all back together and trying to ride it, or did you put it on the center stand, and do a dry run thru the gears? It can help to rotate the engine along with rear wheel while doing this, otherwise, the gears may not move/slide like they should....the engine is usually running when shifting!
T.C.

[ozlad]

Yep still got the side cover off, yes tried it with the bike on the center stand and dry changed it. Will go out an try moving wheel. Am waiting on a new plate as bitzer plate was missing......now if only I can find the original dowel... Thanks TC

[ozlad]

Spot on TC, works like a charm now. Many thanks and I am glad I found this great site.... Very informative and lots of experience out there

[motoman]

original pin sometimes lays in side of case under cover...........if not either made it to the pan or the tranny gears "ate" it and can find slivers of remains trapped in filter housing bolt being stopped by filter.