5th gear issue

[GoRacers]

In my opinion the washer swap is most important here. As trbig said, you could probably get away with JUST that but speaking from experience work the gears also because you don't want to have to do it twice like I did.

It only takes a big job going wrong once to learn that I'd rather do a job right than do it twice.

[trbig]

I think I'll go ahead and modify the dogs before I put them back. I'll check out the fitment before I decided to move the washer.

Yup.. The washer swap is more important to do than the grinding. A grind without the washer swap.. and you'll be back in there in no time and buying another 5th gear because I wouldn't grind them a 2nd time.

[GoRacers]

Got the bike back together today, and I only have two gears. clutch action and operation is good, I can move the bike with the gears I have, but it will obviously stall if I try to actually take off.

Will the shift drum and forks fit back together any other way but the correct way? I thought everything went back together correctly, but I wonder about the shift linkage.

Does anybody have a pic of the shift levers and shift drum position (from the side, behind the shift cover), and know what gear the bike is in for the pic?

Kind of bummed, really don't want to pull it apart again.

[DGXSER]

Not sure it would go back together if you got the two shift forks for the countershaft gears in reversed. They are almost identical, but they are numbered. When making the repair, the starting point is to have it in 4th gear. The following pics are with the transmission in 4th gear.

Here are some pics I took as I took my first one apart....

[GoRacers]

Perfect. Thanks!

Interested in whether I can rotate the drum through all gears manually after pulling the side cover, and whether my shift pawl is attached in the correct position on the drum pins.

Done for the day, though. I'll look into this sometime this week.

[GoRacers]

My shift pawl and lever were misaligned by a tooth.

ALL IS GOOD.

I only put ~3 miles on it, but I can hit the throttle MUCH harder in 2nd than I used to, and it didn't pop out or slip once.

Clutch also feels much better now, not really sure why it is different. It doesn't take near as much effort to pull the lever, and it grabs immediately.

Overall, I am VERY, VERY pumped to have my bike back on the road. Thanks for all the help everybody; this board rocks.