Can't get 5th gear wheel off

[bikerphil]

Marty, that countershaft should go back in without splitting the cases, even with the washer swap, just be patient. With the shaft in position to go back in, slide the middle drive gear and 1st gear and it's collar towards the clutch side of the case and give 2nd gear a tap with a rubber mallet and the shaft should start going in, then return the mid drive and 1st gear back into their location. It might take a few tries but once you find the "sweet spot", it should drop right in. Don't forget threadlock blue on the countershaft 14mm head bolt on the clutch side. HTH

[jetmechmarty]

Phil,

Do I slide the middle drive gear until it's almost off the shaft?

[DGXSER]

Marty,

I always slide the middle driven gear until it is just about to lose contact with the teeth of the shaft. Then I slide first gear off its collar right up against the middle driven gear. This lets those two gears be at a slightly different angle (more straight up and down) than the shaft which lets them slide down to let the shaft line up with its hole and start its way in. That of course lets Second gear move into place and drop down. The tricky bit of my method is working the collar back inside the first gear after it drops into place but before you move the shaft.

Phil seems to have luck keeping the sleeve bearing in place with first gear, but the concept is the same.

[motoman]

+1 using the blue thread-lock..........nah.....don't ask how I know....

[jetmechmarty]

Gentlemen,

Thanks for the encouragement. With a little help from a dead blow hammer and a brass drift, it finally dropped in. I had to walk off at that point. I'll start reassembly when I have more time. The rear wheel only rotates backwards as it sits. Will that sort itself out as I go forward with reassembly?

[Phoenix Rider]

Restarting After Assembly

I did my 2nd gear fix a couple of winters ago. Just a little note that when you restart your bike. After you replace the oil. Take your spark plug leads off and with short bursts of the starter button, prime the oil back through your system until the oil light goes out. You may or may not have already known that but it is a good tip to know.
Just another note. Since I did the TC dremel fix. The torque just about pulls the handlebars right out of my hands.

Good luck,
Wayne

[bikerphil]

The rear wheel only rotates backwards as it sits. Will that sort itself out as I go forward with reassembly?

Install 5th gear and it's bearing cap and the shift forks and the wheel should barely turn in either direction, because the shift drum should be in 4th gear position for assembly. Before putting any covers back on, shift thru all the gears rotating the back wheel slightly if needed, making sure everything is smooth.

[jetmechmarty]

I got the countershaft in, the forks on their shaft, and everything looked great. The middle shift fork was in upside down! So, I'm back where I started, trying to get the shaft back in. Enough for today.

[natemoen]

You will be good at this by the time your done!

[DGXSER]

Yeah, that will ruin your day, DAMHIKIJK!!

Patience is a virtue and I have never been accused of being virtuous. I have managed to re route those shift forks without pulling the countershaft out. But it is tricky at best.

[bikerphil]

Marty, glad you got the countershaft to go back in, just when you think it'll never go, pop, it goes right in, lol. Good luck with the rest of the reassembly. You are officially a GURU now.

[jetmechmarty]

I guess if I did it once, I can do it again.

[DGXSER]

Thats what will make it maddening though, you know it WILL go in, but danged if anyone can tell you exactly how. And it will surely not drop right in again, so you just wiggle and jiggle and mess and fuss and then all of a sudden, HEY..IT WENT IN!!!

[natemoen]

Absolutely man!

[planedick]

Turning over

I have done 4 tranny fixes so far and turning over was done alone except for the one I just did last week. I tie the rope to the lower part of the triple tree, front wheel off and lift the bike up till it's about a 45 degree angle then turn it over and set it down on a stool where the tank was. Jason may have some pics of this, I'll ask and maybe post them here....