Shifter Reassembly

[jetmechmarty]

My bike is upside down and in fourth gear. Will I be able to reassemble the shifter that way or do I have to somehow get it into 2nd gear?

Sorry, but it was December when I took this thing apart.

[bikerphil]

Marty, click it into 2nd before putting the cover on making sure the index marks line up on the shift drum and the shifter pawl. You can reassemble the shifter mechanism with the transmission in any gear, just line up the two dots for proper orientation.

[natemoen]

Anyone have a pic of it lined up properly?

[DGXSER]

This is the tranny in fourth gear with the shift pawls in place, dots lined up.



Fourth gear position is only for the purpose of removing and installing the countershaft and athe shift forks. I have never looked into why it is critical to be in fourth gear, I imagine it relates to the position of the gears and the shift forks and beable to slide past each other. Anyway, once ou have the countershaft back in place and the shift forks installed. What gear the tranny is in is irrelevent.

[jetmechmarty]

The service manual says to put it in 2nd gear for reassembly. Why? From your picture, it doesn't look like it would make any difference.

[CatatonicBug]

The service manual says to put it in 2nd gear for reassembly. Why? From your picture, it doesn't look like it would make any difference.

It doesn't matter. I keep mine in 4th all the way from beginning to end when doing the dremel fix. Never needed to switch to 2nd gear. It's just a cylinder, and it's position doesn't matter in this case.

[motoman]

Position DOES matter..........if your gonna check shift-pawl index.......HAS to be in 2nd gear to do this........and a good thing to check if shifting doesn't "feel" quite right or just to double check going back together.

[jetmechmarty]

No matter. I got it into second.

[natemoen]

Well I am glad that us the way it is. Didn't see the dots but thats where I put it anyways.

[DGXSER]

Position DOES matter..........if your gonna check shift-pawl index.......HAS to be in 2nd gear to do this........and a good thing to check if shifting doesn't "feel" quite right or just to double check going back together.

I'm interested in why. The shift pawl as shown in the picture simply rest over the pins on the shift drum. In any gear, the at rest position goes back to the dots lined up, seen it, does it every time. Honestly, I have never taken it out of fourth until I have the shift pawls in place as shown and then only to shift through all the gears. Never had any problems doing it that way, but perhaps I am just lucky.

[bikerphil]

There are 2 different sets of marks. The set of LINES on the shift drum/pawl and the set of DOTS on the parts with saw teeth. The LINES must be calibrated when in 2nd gear. The adjustment for this is the eccentric screw/nut near the large torsion spring. The DOTS just need to be aligned, doesn't matter which gear.