03 XB9R, gears don't line up? video diag

[SausageFingers]

What do you think? It could be an incorrect gear set or I'm missing something simple.

http://www.youtube.com/watch?v=2pkLCweNoKQ&feature=youtu.be

 

[kab]

Sorry I can't help but great video

 

[EvilRX]

make sure the shift forks are in the right place or check the others

 

[CBi]

Do you know what year the "new" gearset is from?

The XB trans was redesigned in '06, from what I recall.

Is there any damage to the old gearset other than the shift fork? If so I might be inclined to just put a new shift fork in there and put it back together, as long as everything else looks good.

 

[EvilRX]

btw when the nub that is on the end of the shift drum is up it should be in neutral

 

[SausageFingers]

The new gearset was advertised as 2003 XB9 with 14K miles, but who knows? it's obviously different.
Yes, there is one gear on the countershaft that is very blued and scratched up, and on the mainshaft the sliding gear is also blued and some fork remains are wiped in the track.

The shift forks are all the same, and the drum pattern is pretty straightforward. It's impossible to misfit them, install backwards, etc.

 

[EvilRX]

are you 100% you have the main shaft all the way in

 

[SausageFingers]

are you 100% you have the main shaft all the way in
- Hm, I THINK so. It bottoms out in the press. I'm going back to the shop to install the old gear set, completely, and see if the problem is still there. BRB

 

[SausageFingers]

WIN WIN WIN! VICTORY! Plus a bonus question at the end!
Headphone users beware: smacked the camera a few times.

http://www.youtube.com/watch?v=HlJ3qtYdVsE&feature=youtu.be

 

[CBi]

Good deal SF! And props to EvilRX as well for pointing you in the right direction.

As far as the alignment pin, make SURE it isnt for the case halves, do a visual on all the case bolt holes and see if it fits in anywhere. Maybe a double check with the parts book too.



[up][up][up]

 

[Bullxb12r]

And make sure the trans is in 4th gear when you put the case halves back together

 

[EvilRX]

if you dont know already make sure you remove the neutral switch and use smothing to hold the gear detent out if not it won't go back together correctly

the dowel looks like the ones that are on the primary cover, the dowels on the engine are small 3/16 thick x 1/2 long

 

[Cecilsan]

the dowel looks like the ones that are on the primary cover, the dowels on the engine are small 3/16 thick x 1/2 long

I concur with EvilRX, I remember taking apart my primary on my Blast to work on the primary shoe. Found a dowel very similar to it on the ground thinking where the hell did this come from. Found it went to the primary case

According to my parts manual there is a spot directly above the main shaft where one goes. Watch anywhere from :45s - 1:21 in your video and I think you can see one just to the upper right