Z1 Gearbox rebuild

[Glen]

Cases now Aquablasted, new Gasket set, Bearings and Seals.
Top and Bottom cases are back together. Selector Mechanism assembled, everything looks as it should. I have a Haynes and Clymar Handbook.
I have watched Alan Millyard Z1B Engine Rebuild Episode 3, probably too many times now. Alan Millyard advises to check that all gears can be selected before going any further. Wise words I think. There is a "lockout mechanism" before second gear with Ball Bearings that "spin out" when engine is running, he spins the shaft with fingers and thumb and changes gear with JIS screwdriver. All gears select nicely.
WELL it works for Alan but NOT for me. I can find neutral ok and even First Gear, but that's all. Everything may all be ok, but I want to be sure now while the engine is on the bench.
Removing the Selector Forks, everything moves freely.

[zed1015]

Unless the gears have been off their shafts and then mis assembled it's pretty much impossible to cock it up.
With the engine sat on it's sump you really have to flick that output shaft round fast to get those three balls to throw out.
It's much easier having the engine clutch side down with the output shaft vertical so that your aren't working against gravity.

[Glen]

Ok, the engine is upside down, I will turn up the right way.

Alan Millyards You Tube video. Go to about 7 minutes in. Link is:
https://youtu.be/ajIgSFZkSfE

[zed1015]

That Millyard vid doesn't show him spinning the shaft.
You want the engine sat on it's clutch side with the output shaft facing up/vertical.
This allows all the balls to run out sideways with little effort when you spin the shaft .
When you do it with the shafts horizontal there's always one ball bearing that is working against gravity so you have to give the shaft quite a quick flick whilst changing gear at the same time.
The other option with the shafts horizontal is to use a battery drill and socket on the sprocket nut to spin it fast enough.