missed a small step in assembly with 516

[Steptoe]

put 516 back together as per manual,,,,,,except for checking the claw and selector drum marks
didn't put into second like your supposed to

have completed rebuild and now can't get to select any gears

was up to riding it and can't get a gear

MY QUESTION do I have have to go backwards to that step or is there a way we can turn the drum to the right spot

the selector claw doesn't sit over both pins
have tried turning drum, with no success

[3Phase]

Well, at least the side cover is off. Is the bike stuck in neutral?

The shift drum can be difficult to move so put the foot shift lever back on and tighten the bolt to hold it. Turn the rear wheel slowly back and forth while you try to shift up and down.

Yes the alignment has to be checked but you already have the side cover off so it shouldn't be a problem. The alignment centers the assembly so the foot shift lever travels the same amount for an upshift and a downshift. Unless something is really, really, (really!) off it should work well enough to shift out of neutral into 2nd gear so you can check the alignment. If the shift pawl (claw) can't catch the pins on the shift drum when you move the foot shift lever it's not assembled correctly.


Regards,

Scott

[DGXSER]

Shift forks....The middle shift fork is pretty easy to identify as it is so small, but the other two are identical, except that they are not equidistant form each end. They therefore are not interchangable. I always remember that the longer side of the mounting bar on the fork goes to the outside of the engine case for that side. If you got them in backwards it coud be your problem.

All of the pins are in the shift drum? You aligned the dots on the shift pawls when assembling?

[trbig]

Since I don't have a manual for seeing what 516 is, do you have any pics? It is possible to put the shift forks in wrong. They are numbered 1-3 with #2 being the small one. The #1 goes closest to the shifter.

I've never had it in any particular gear when I put one back together, but I split the cases to do mine. If you have the shifter cover off, take a pic for us. It may be something as simple as the shifter spring being off.


Tod

[TopCatGr58]

Hey Step,

Most folks have already given great info! When I was helping a fellow XSive fix his tranny, I had the shift pawl and lever gears aligned with the dots, and then let the fellow Xsive put the cover on, but he inadvertantly pushed and then pulled, and then pushed the cover into place, and that caused the shift lever to pull out, allowing the dots and the teeth to slip many teeth, got it all together and only had 1st and neutral! Thought I had really messed something up...pulled the shift cover back off and found the misaligned lever teeth and dots. Put it back together properly aligned, and viola, had all 5 gears !! I could be something as simple as that???

The shift lever slides very easily in it's mounting hole in the case, so you have to be careful to get the cover aligned and then just push the case down onto the lever shaft with no in/out wiggling, or the seal grabs the lever shaft, and pulls the lever away from the engine, and the lever gear teeth slip!
T.C.

[Steptoe]

will check that now

sounds like DG might have it right ,,

TR 516 is the other bike I've been working on for a mate,,

just wanted to see what you fella's thought before tearing into it,,,

will let you know how we go

[DGXSER]

Tod, IIRC, He has been calling it 516 for the serial no. as both are the same year and model.

[fabricgator]

Thats what I was thinking,

516 must be the s/n....

[Steptoe]

all better

I answered my own question,,,
had to go back to putting the cases together,

remembered TC had helped a fella, "AL" some time ago ,,going into the box from underneath, so tried that first.

having the selectors in back to front,{how } the gears weren't going to come out the way TC got at them,

so a 3 & 1/2 hour operation had the motor out, split, selectors right way round and back together with things working as they should

thanx again for input and seconding my own thinking

[3Phase]

... a 3 & 1/2 hour operation had the motor out, split, selectors right way round and back together with things working as they should

Right on! No messing around just dive in and do it!

So, how's it run?


Regards,

Scott

[Steptoe]

weelll

a damn sight better than before,,,, we can change gears now

[DGXSER]

Glad that fixed it for you. Interesting you had to go to pulling the gears though, typically, you pull the shift forks before you get to pulling the gears, and they can be taken out and switched right way around. But then, I've battled with the shift forks before longer than you did splitting the cases.