Ugh. Tranny Woes.

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Buellaucracy

Well-known member
Joined
Jun 14, 2011
Messages
139
Of course, I get the damn thing completely put together after replacing a faulty fork and dog, and engine overhaul. Now she won't go past 2nd. I may have gone through the other gears but it may have been just me wishing. Shift lever hasn't been through any trauma and worked fine before.

If anyone has any suggestions let me know. I really don't want to split the cases again as I was just doing it this past week. Lol.

Clutch was adjusted, no change.
Running or asleep, all the same.
She just refuses to shift into 3+.
If I did go through the rest of the gears(and wasnt hallucinating) that makes me think it isn't internal tranny related.
 
Sorry to hear you're having issues after all that work!
I recently rebuilt my transmission and was worried about something similar happening.
Anyway, I'm sure you followed the manual to a "T". I know I checked and triple checked that everything was good to go before sealing everything back up.
So this is the only thing I can think of that you may have over looked....
Are you sure the little spring inside the shift shaft butterfly mechanism is positioned correctly? If it is out of place, which is really easy to overlook, the shift shaft won't engage the shift drum correctly. This might be something you want to check before splitting the cases AGAIN. If you do have to split your cases again, you have to take the primary apart anyway. So it's worth a shot.
Good luck!
 
^ I would lean towards more the second option you posted up as the first one would likely lead to just the shifter not returning to center. But maybe that's the issue! Maybe he goes down to first just fine, then up to second just fine since its the opposite direction, but cant go up any more after that since it wont return back to center, resetting it. You may be on to something!

But since we are talking springs, maybe check the ones that connect to the lever arms on the shift shaft, the ones that let the drum spin one way. Those could have came off but I would guess that then it wouldn't shift one way at all. It's hard to say correctly right now. Some more info would be helpful.
 
Great info guys! I really needed the insight. I'm going to explore those ideas today. If I find the culprit I'll let you guys know asap.
 
Well..it seems that it was the primary case bolts. The book calls for 15-19ft/lbs. If I recall correctly I set them all to 18lbs. I neglected to mention that I replaced the shifter drum during my rebuilt. Apparently 18lbs was too much. I backed the six off around the Drum/Counter/Main and started at 10lbs working my way up to see where I started to lose functionality. The drum started to get hung up around 15lbs. What the hell? So they're all torqued at 13lbs with red loctite and the parimeter ones are set at 17lbs. Everything seems to be rolling wonderfully now and the bike will be back on the road tomorrow.

Thanks for the help again guys, I never would have thought of that and probably would have started to pull the motor by now. Your guys' input has literally saved me hours of work and frustration.
 

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