Stuck

[fredintoon]

Thanks Guys !

I'll try all you all have suggested.
I did get the cluster back in magically but did not put the #3 fork on and it will not go on with the cluster in place.
Took a bit to get it back out put the #3 fork on and spent another 4 hrs. on my back to no avail.
Like I said I'll try all your suggestions, maybe again tonight or next day.
I'm sore and beat up at this point but I'm not giving up, laying on a rug helps but at 60 my shoulders head and arms are sore but not done.
12 hrs. from now might not be able to move maybe take a break and back at it ?

Thank You All ! Done };~)

Hi Done,
eight hours on your back, eh? Is the fleet in?
Seriously though, all the successful photos show the bike on it's side or inverted.
Mebbe the longest way round is the shortest way home for this job.
Turn the bastard upside down.
That way you can work standing up, crap won't fall in your eyes and gravity will be a help instead of a hindrance.

[donebysunday]

Hi Done,
eight hours on your back, eh? Is the fleet in?
Seriously though, all the successful photos show the bike on it's side or inverted.
Mebbe the longest way round is the shortest way home for this job.
Turn the bastard upside down.
That way you can work standing up, crap won't fall in your eyes and gravity will be a help instead of a hindrance.

Hi Fred went back it it to no avail for another 2 hrs. Sat. night. Came out so easy thought it would be a cake walk. Could not move yesterday so watched all the games. Now it's going to be in the mid to upper 90s, it can wait. Hotter next day then cooler into the 70's, should be back in shape to tackle this thing again. Magnified safety glasses, but have not had anything fall on me yet ?

Thank You ! Done };~)

[BA80]

Many others have said that they can do it without but the only way I've ever been able to get it done is to remove the shift drum. The gears will come out and go back in pretty easily that way and I ALWAYS do the washer swap.

The only drawback to taking the shift drum out is the detent is a BITCH to get back in but it can be done with patience and a few select swear words.

Use a piece of clothes hanger in place of the rod the shift forks ride on during assembly and it will keep them in place while you get things lined up.

Once you get the gears and forks where they belong then insert the shift drum and hold the detent down with a screwdriver and fight it until it finally slips into the lowest point in the detent wheel on the end of the shift drum. You'll have the detent and spring shoot out when the screwdriver slips off a few times so a good idea is to put an old blanket or something similar down so it doesn't bounce off into never never land.

I have found this to be the easiest way for me, also it's much easier if the bike is flipped over on it's back instead of you.

[donebysunday]

4 The tricky part is that the inside of the case has a "pocket" for the case side hub of the middle driven gear to fit into, it is a PITA to get the hub over the lip and into the pocket. There is a small opening in the ring that helps it get into place. This is where you have to manipulate things just so to let that hub get into the pocket.

4 Once you get that hub into the pocket, the shaft will be able to line up with the bearing, and by this point, first is back on its bearing.

I am still pleasantly surprised when all my cursing and swearing and praying add up to it magically going into place, but these clues and techniques have cut down on the number of attempts until the magic happens for me. And BTW, I ALWAYS do the washer swap, so it does go in with the washer swapped.

Did try all suggestions from everyone. Thank You All !!!!!

Don's #4 is what I think got it for me, I think the middle drive gear came off the spline getting past that little edge to the pocket but once it was aligned the cluster slid together and all the gears are shifting up and down.
Could that little lip that keeps the middle gear from going in be cut off ?
I did use a 3/16 rod to hold the 3/2 shift forks in place.
I should have written down the side of the forks that had the numbers on them as I could swear number 3 fork was facing the left side but I followed the pictures you all offered. By the way the church bells started ringing just as I got it to slip in ? ? ? I did not swear once during the entire 14 hrs. I struggled with it, yes another 4 hrs. this morn. before it got hot, now over 90°F.

Thanks again !!!!! Done };~)

[jetmechmarty]

My bike was like this for three months, maybe more. I gave up several times. The shaft fits, even with the washer moved. As everyone else has said, it takes just the right combination of naughty words. I finally got it together and then discovered that I put the forks in upside down. DOH! Don, don't you wish you had the bike upside down right now? I told you so.

[trbig]

LOL.. Marty, I see the tool every good mechanic owns.. The BFH!! Right next to your gears! lol.. Did they finally need a little coercion?

[jetmechmarty]

LOL.. Marty, I see the tool every good mechanic owns.. The BFH!! Right next to your gears! lol.. Did they finally need a little coercion?

Yes Tod! It's a soft face dead blow hammer, and it was necessary. The bike was on its back a long time, but I was gone three weeks at a time. It was worth the trouble, because it sure works great now!

[rdmcguy]

Afreat pic.

That pic of your bike upside down is worth a thousand words.
Maybe a good caption would be "YOU WHORE"
I just discovered that my most recent buy Has the 2nd gear issue,
Am glad that perserverance paid off

[jetmechmarty]

Am glad that perserverance paid off

I'm pretty sure my bike works better now than it did when it was new. It shifts real nice. I was lucky enough to have new gears to put in mine.

Don, stick with it! You'll figure out the trick.

[donebysunday]

I'm pretty sure my bike works better now than it did when it was new. It shifts real nice. I was lucky enough to have new gears to put in mine.

Don, stick with it! You'll figure out the trick.

Hi Marty !

Good to see your back ah front and the bike is on it's back but now working great !

If you check my post #19 over you will see my not swearing and 14 hrs. on my back I GOT IT !!!!! Just as the gear cluster slide into place the bells at the church down the street started ringing, no swearing bells ringing was I just being tested ? ? ?

[jetmechmarty]

Did you move the washer, or give up on that?

[Bigfoot]

Glad to hear that you got it fixed. I have done it numerous times with the bike on the centerstand. It can be done. A stiff wire, like a coat hanger helps keep the shift forks from hitting you in the forehead. A big rubber mallet helps, mostly to vent frustration.

[donebysunday]

Glad to hear that you got it fixed. I have done it numerous times with the bike on the centerstand. It can be done. A stiff wire, like a coat hanger helps keep the shift forks from hitting you in the forehead. A big rubber mallet helps, mostly to vent frustration.

Thank You Harry !
Did use a 3/16 wire through the shift forks and church bells rang just as the gear cluster slid into place. No hammers of any kind were used in this repair ! No swearing/cussing, just 14 hrs. of repeated tries and re-reading all the great info everyone on this forum shared with me.

Thank You All !!!!! Done };~) Oh ! Yes Marty I did the washer swap.

[motoman]

Glad to hear that you got it fixed. I have done it numerous times with the bike on the centerstand. It can be done. A stiff wire, like a coat hanger helps keep the shift forks from hitting you in the forehead. A big rubber mallet helps, mostly to vent frustration.

Well, looks like we are in the minority doing it on the centerstand Harry. Doing this myself, would'nt even consider flipping that beast, aside from having to remove fairing/luggage assembly and draining ALL fluids. Too many things that can go wrong on top of getting hurt. Putting bike centerstand up on a 6"x6" and blocking front wheel so it don't rock forward gave plenty of room under there to R&R that lower shaft, and a nice piece of indoor/outdoor carpet to lay on. Plus everything was still in correct orientation. Not being in a hurry, after pan removal I sprayed bunches of Brak-Kleen up in there and let it drip for a couple days prior to diving under there. Makes things nice and dry and no dripping. Gravity also helped for the two far side shift forks to just nicely drop in place on their associated collars once shaft was in place. Even if I ever did a naked Special, would'nt flip it. If I had to do over again, after wedging rear wheel to remove that large bolt and in fourth gear, I would remove rear wheel and rock bike back as far as whatever is needed on the centerstand for the extra room under there. Aside from forks dropping out upon shaft removal, they can be wedged up in there above things to get shaft assembly back in. Those forks are least of your worries compared to getting that shaft to magicly finially drop in place.

[BA80]

This is is how I did the tranny on Okie last fall.



I think I'll flip it next time. 600lbs dangling over you is a little unnerving.