Practice - needs help.

[Aches n Pains]

Recently I was given the bottom half of the engine from a 1979 XS11 Special. Seemed like a great opportunity to rehearse the process second gear Dremel fix as outlined in TopCats fantastic walk through ( http://www.xs11.com/xs11-info/tech-t...lwalkthru.html ).

I mounted the engine upside down on a Workmate with the top end studs sticking through the top of the Workmate. Good solid platform to go at it.

Things were going great but I may have gotten a little greedy at:

"Next, slide the shift fork shaft out slightly just enough to clear the most distant fork, that's engaging gear #5, and let the shift fork slide down away from 5th gear against the shift drum."

I slid the shaft fork out all the way - sorry, Topcat. The next step is to "slide 5th gear out the side of the engine" and mine won't move. Suspect I'm stuck on one of the shift forks. Any thoughts on a next move?

Looking into the transmission




Right side of the engine - note that shift fork shaft has been completely removed.




Left side of the engine looking at 5th gear





My next thought is to remove the shift drum to see if I can get some of the loose parts out that may be holding the gear in place.

Thanks for your help,

Doug (Aches n Pains)

By the way, I highly recommend doing an autopsy on a dead engine. Great to see how all the parts really look and fit together. Also seems to be a pretty good source of parts. Amazing how clean this "dead" engine is.

[BA80]

That shift fork should drop down out of the way enough to get that gear out.

[DGXSER]

The purpose of sliding the shaft out, is to let the actul shift forks move. You can see the shift fork is still fully engaged with 5th gear. Push its pin out of the slot in the shift drum and let it drop down so it is no longer keeping 5th gear form sliding out. You can manipulate it to pullit out of the engine completely, but only need it to clear the gear.

You will need to do the same with the 2nd and 1st gear forks before you can slide the shaft to get the entire countershaft out.

[crazy steve]

You don't have the trans in fourth gear, and that will prevent you from getting the 2-5 fork down and out of the way...

[Aches n Pains]

Steve, any suggestions on how to get it into 4th gear at this point?

[Aches n Pains]

Also, how do you know what gear it's from that view?

Thanks

[BA80]

With the shift fork shaft out you should be able to just reach in and push the gear over. You may need a screwdriver or something.

Actually, if all the shift fork pins are out of the shift drum you might be able to remove it and make yourself some more room.

Be careful, those gears are sharp and cut fingers easily.

[crazy steve]

Also, how do you know what gear it's from that view?

Thanks

Looking at your first pic (with the fork shaft still in place), note the position of the middle (3-4) fork. Right below it (in the pic) the groove 'curves' to the right. The shift drum should be turned so that fork pin is in the curve, which will be 4th gear. Rotate the drum until it is...

[DGXSER]

I just looked at the shift drum pins and compared it to the one in the tech tip write up. It is off, you do need it in 4th gear.