shift fork shaft shafting me

[DGXSER]

Anyone ever find that the shift fork shaft will not slide out due to the middle driven gear?

I can see the notch in the shift fork shaft hitting on the middle driven gear ( the one the notch is there to clear), and it will not slide past it. As many times as I have done this repair, I have never had this issue before.

[bikerphil]

Not sure if it matters but is the tranny in 4th gear?

[DGXSER]

yes, transmission is in 4th gear Phil.

[XS11UFO]

Only done it once and with the engine out and on a bench I couldn't get everything out and back in without splitting the case, just figured I was dumb. As it was I spent nearly as much time messing with it as I did splitting the engine with a lot less frustration.

[trbig]

Take all the circlips off the shaft, dummy!

I've never had that problem either. Easiest solution then is to pull the clutch basket and remove that gear.

[DGXSER]

Trust me Tod, I checked it more than once as I am more than capable of spending 30 minutes pulling and tapping o find I forgot a circlip.

I thought about going the other direction with it, removing the gear, but I would also need to pull the positioning pin. Not sure how much torture it will take to get that out, it has not come out with simple tugging with pliers so far.

I have the engine out on the floor of the garage, I may just go ahead and split the cases, seems like a bit more effort than I intended since tis is for inspection only as I have no idea how well the gears hold.

[DGXSER]

Well I finally convinced it to give up. Just took a little more blunt force trauma than I normally like to apply during internal engine procedures. I will say that having that kickstart gear in place makes pulling those gears an entirely different kind of PITA than without it in there.

[Ken Talbot]

Now that sounds familiar.

From an old archive!

[DGXSER]

Yes, I found that my 5th gear dogs and second gear slots were practically brand new. So my plan was to simply swap the washer on 2nd gear. However, after an hour or so of jiggling, pulling, manipulating that shaft like a teen ager with a good book I still could not figure out how to get those gears to decide to come out. It really was the shaft holding things up. It moves out enough to clear the case, but not that ring around the middle driven gear. The slot for it to slide out of is on the same side as the kick start gear, so it can not go there. Second gear is tight against the main shaft gear below, so it and the shaft can not slide out any further. And the shaft can not tilt enough to let second gear clear that gear.

So I put it all back, and since I have the engine layin on my garage floor, I am considering splitting the cases to make it much easier. Just one of those phobia things that I have never split the cases before, so I am apprehensive about it.

[trbig]

It's just like a color by numbers or dot-to-dot. Just follow the seam and remove what's bisecting it, like the middle drive and the couple pieces under the shifter cover. (You'll need a torx bit.. T-20 if I remember?) Don't forget the one bolt under the breather cover. Also, don't forget to drain the fluids... They can sure make a stinky mess if you forget the middle drive fluid... Then I like to poke holes in a piece of cardboard, and as I remove the bolts, stick them in a hole with the number that correlates. 35 bolts/holes... Numbers start at 34 and go down, but you'll have two number 11's at the front of the motor.

You'll also need the cams pulled so you can let the cam chain down into the bottom. (Good time to change it if many miles on?) Make sure and measure the shim clearance before you remove so you just have to do that once. After you remove the cams to get the chain loose, put a couple cam caps back on each cam to keep the buckets from sliding out when you flip the motor.

[BA80]

Or, you could do it as I have SEVERAL times and take out the shift drum. As I've stated before the most difficult part of reassembly is getting the detent back in but it's just kinda frustrating, not really hard.

With the sift drum out of the way the gears almost fall out. But, most people just want to do it the hardest possible way for some reason.

You need to look close at those dogs and slots. They can look good but in actuality be worn. Look at the contact points. If they are even slightly rounded they are worn. You don't want to do it twice like I had to last summer.

[trbig]

As I've stated before the most difficult part of reassembly is getting the detent back in but it's just kinda frustrating, not really hard... But, most people just want to do it the hardest possible way for some reason.

Agreed.. That's why I just split the cases. Plus, it gives a chance to check out everything else in the motor, like the bearings. It's easier, and probably quicker for me, especially with a motor out and sitting on a bench, to just split it than it is to fumble and fiddle in frustration with small parts in tight places. With his kickstarter in, the space will be even more limited.

BUT.. it's a free country and you can continue doing things the hardest way possible if that's the way you personally want to go..

[BA80]

With his kickstarter in, the space will be even more limited.

Not with the shift drum out of the way.

[trbig]

Not with the shift drum out of the way.

Put the beer down before posting.. We were talking about the reassembly problems (Hence the quote) of getting the shift drum and detent IN. You do it your hard way, and I'll do it mine I guess.

[BA80]

I'm at work, not drinking and I did it TWICE in as many evenings this way after work WITHOUT removing the engine and WITHOUT splitting the cases.

That's why I said take a good look at those dogs and slots. I swapped out the whole shaft with a good 2nd and didn't look close enough at 1st. Wend from a 2nd gear problem to a 1st gear problem.