gearbox issue

[Wrigers]

Got a bit of a dilemma here chaps, been on with installing the block and barrels into the frame. Now ive called myself to double check everything when bolting the crankcases together , gear selectors right way round as per numerous videos and pics etc.
Block now in, clutch on, starter clutch on, but when ive turned it over it won't select nuetral. No matter what gear i select by turning the engine as i go, the drive shaft sprocket always turns.

Ive done some serious head scratching, to the point were i am now thinking of taking the block back out, removing the sump and taking another look to see if ive made an error on assembly. Bugger, it was going so well up to that point.!!!! .
Any ideas wojld be much appreciated. Paul

[Philippe]

Hi Paul

do you have a workshop repair manual?
If you do; read it again and check all the steps.
It's crucial to set the selector drum in the neutral position, to slide the shift fork on that drum in the right position( the short side of the shift fork must point to the left side of the crankcase) and that the the shift fork bolt rests in the middle groove of the shift drum.
When you turn the sprocket of the drive shaft ,does the cranckshaft turns allso? If the cranckshaft turns then there's something wrong.
If you don't have a shop manual, there's a link somewhere to download it, recently it was set on the forum but I don't know where exactly.
Hope you can work it out!
Good luck
Philippe

[Wrigers]

Thanks Philippe,,, yes i have a manual and thought id read everything. I did research the bit about the shift drum position but i may have had a senior moment somewhere along the line.. thanks again.

[zed1015]

How are you spinning the engine to select all the gears ?
Have the 3 detent bearings been removed to disable the positive neutral finder so that all the gears can be selected at a standstill.
If you are spinning on the starter whilst selecting gears it's likely the you are going past neutral into second and third etc.
If you are not spinning on the starter and the detent bearings are still present it's unlikely you will get any gears other than 1st and neutral.
Are you just observing the sprocket turning free without putting drag on the sprocket via a chain or holding it still
The sprocket will always turn even in neutral if there is no chain on due to general drag in the cluster.

[Wrigers]

Hi Zed, I'm turning it over via the bolt on the generator/starter clutch, and yes ive grabbed the sprocket phisically.
Not sure what bearings you are referring to, i just re installed the detent as per the book.

[zed1015]

By turning the engine by hand you won't be able to select any gears other than 1st and Neutral.
There are 3 ball bearings in the gear cluster output shaft that work by centrifugal force which stop second, third etc being selected unless the bike is moving or on the mainstand with the wheel spinning.
Wiggle the sprocket by hand while lifting the gear lever ,you should be able to select neutral by doing this.

[Wrigers]

Ok, ivd just been out and tried your method. No joy.
with the detent in the netruel position, sprocket turns with engine.
Gear leaver worked down one, nothing still turns.
im going to satisfy myself and remove the sump to inspect if anything is obvious.

[marmck]

There are rebuild videos on you tube 4 Zeds , you might spot something you missed ,hope this helps

[zed1015]

Ok, ivd just been out and tried your method. No joy.
with the detent in the netruel position, sprocket turns with engine.
Gear leaver worked down one, nothing still turns.
im going to satisfy myself and remove the sump to inspect if anything is obvious.

There's not a lot to f**k up when fitting the box,especially if the gears have not been off the shafts.
It's impossible to get the selector forks wrong as they only go in one way but you may have one of the forks off to one side and not sitting in its track either in the selector drum or on it's corresponding gear.

[Wrigers]

I'm thinking the same. Like you say the gears are straight forward. The problem must be with the selector forks.