Fun in the garage on a friday night......

[trbig]

If your not removing the drum I can't see how your removing the shift forks and if your not removing the forks I don't see how your getting the gears out.

Sorry, Greg. I'm no help in that since I always just pull the motor and split the cases to do this job. I tried it once with the motor still in the bike and ended up fighting with it so long that I decided I would have been better off and quicker (With a lot less cussing) to just jerk the motor out and do it. I was at the point a while back where I was taking the motors out so often for stuff that I got pretty good at it.. and was trying to figure out a way to get quick release pins installed.. lol.

[madmax-im]

Sorry, Greg. I'm no help in that since I always just pull the motor and split the cases to do this job. I tried it once with the motor still in the bike and ended up fighting with it so long that I decided I would have been better off and quicker (With a lot less cussing) to just jerk the motor out and do it. I was at the point a while back where I was taking the motors out so often for stuff that I got pretty good at it.. and was trying to figure out a way to get quick release pins installed.. lol.

Tod back in'09 a friend up in Ontario repainted my engine and frame. In 25 mins he had the engine sitting on the floor...and we had just taken our bikes for a cruise beforehand. Rode along the St Lawrence Seaway and decided i want to use it for a backdrop when the bike was finished...it was prolly the best it had looked in 27 yrs (at that time)

[BA80]

Sorry, Greg. I'm no help in that since I always just pull the motor and split the cases to do this job. I tried it once with the motor still in the bike and ended up fighting with it so long that I decided I would have been better off and quicker (With a lot less cussing) to just jerk the motor out and do it. I was at the point a while back where I was taking the motors out so often for stuff that I got pretty good at it.. and was trying to figure out a way to get quick release pins installed.. lol.

It's not too hard to do in the bike, it's actually easy with the bike flipped over but I didn't want to take the mirrors, controls, seat and bar off. Harry said the shift forks will come out if the tranny is in 4th gear when you pull the fork shaft out so I'll give that a try when I tear into it again next weekend.

Tod back in'09 a friend up in Ontario repainted my engine and frame. In 25 mins he had the engine sitting on the floor...and we had just taken our bikes for a cruise beforehand. Rode along the St Lawrence Seaway and decided i want to use it for a backdrop when the bike was finished...it was prolly the best it had looked in 27 yrs (at that time)

Yeah, the engine comes out pretty easy if you have help but it's a real PITA by yourself. I swapped out this engine by myself 3 years ago.

[trbig]

Yeah, the engine comes out pretty easy if you have help but it's a real PITA by yourself.

Almost always do it myself. No big deal, but you will have to put your beer down for a second to get it out of the frame.

[BA80]

Almost always do it myself. No big deal, but you will have to put your beer down for a second to get it out of the frame.

Yeah, you've had more practice at it than me.

When I did it by myself I used one of those cheap little floor jacks and spun it on that and then rolled it out onto a milk crate.

But your right, I did have to put my beer down.

[motoman]

If your not removing the drum I can't see how your removing the shift forks and if your not removing the forks I don't see how your getting the gears out.

The red arrow points to the detent star on the right end (clutch side) of the shift drum.



This little bugger here......



Here's a pic of it in it's receptical with the spring below it...

.

You don't take that out to get the secondary shaft out? I need to know how you do that.

Looks like I've lost what the issue is too Greg. I did mine on the centerstand a few years back and all that was done was to have it in fourth gear initially. That lower shaft moves across barely enough to drop out of right side bearing, and of course shift forks just fall out. Going back, #1 fork can be left out till your ready to put the gear back on that left side. The other two, going up above with them a bit higher will hang up allowing you to get shaft/gear assembly back in. Reached up and jarred the two shift forks and they fell right into place. Then put the #1 fork in place since theirs plenty of room, then gear back on and bearing retainer cap. IMO, on the centerstand with a short 4x4 under centerstand gives a person plenty of room to work, plus gravity IS a help gong back together. How you have your bike hung Greg should of worked in the same manner. Only thing with blocking under centerstand for the extra room is you need to raise and block under front wheel and front of it to keep it from pitching forward. Now since your trusty come-along may not be so trusting, you would have the same access by puttin' on the centerstand, remove back wheel and rock bike back as far as you want on the centerstand and a bit taller blocking under front wheel or stands under frame. Now you have the same attack as it was hanging, but safer on the ground.......JAT, and would be the only difference I would make if I had to do one again. Flippin' the bike strikes me as the house/lite bulb thing....and how many it takes.......well, U know the rest.

[BA80]

Yeah, I'm finding out that that shift drum dosn't seem to need to come out. I've only done one before and that was on the 79 I'm putting together. I changed the shift drum on that because the star washer was broken and there was a couple pins missing and it just seemed easier to just shove a good complete drum in there.

I pulled it thinking it needed to come out because my old memory isn't working as well as it used to. If I have trouble with that shaft again I may just pull it again because it makes it real easy to work with those gears. That detent will drive you nuts trying to get it back in but, it's not impossible.

[DGXSER]

If you look at the tech tip you will see the procedure does not remove the drum. You do pull the shift fork shaft out, and then the shift forks can be manipulated around the drum and the countershaft gears. Getting the shift forks back into place can be a bit of a PITA, and other times they just seem to drop into place like they had a homing signal of some type.

I do know I have done this repair five or six times now and never pulled a shift drum out.

[BA80]

If you look at the tech tip you will see the procedure does not remove the drum. You do pull the shift fork shaft out, and then the shift forks can be manipulated around the drum and the countershaft gears. Getting the shift forks back into place can be a bit of a PITA, and other times they just seem to drop into place like they had a homing signal of some type.

I do know I have done this repair five or six times now and never pulled a shift drum out.

I see that now Don, I'll be pulling them back out next weekend to repair first gear. I just remembered taking it out on my 79 but I forgot it was for another reason.

This next time will be my third endevor. I WON'T make that mistake again.

[Rasputin]

You are just having fun with us right BA?

[BA80]

Actually no. I really thought it had to come out.

It does make wrestling that gear shaft out really easy though.

[BA80]

AARRRGGGHHHH!!!! Almost done with round 2 with the gears. Everything better work right this time.

Got the newly reground 1st gear in. It wasn't all that bad but I knew it would only get worse.

I tried taking it apart with the shift drum in........forget that! Pulled it out again and the gears slipped out and back in with ease. I had to fight that detent again but at least you know what you have to do.

I'll finish the pan and side covers in the morning. I'm whipped.