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May 21st, 2007, 11:48 AM   #1
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Gear selector drum (fixed!)

Need some help with reinstalling the selector drum and the position star on my 2002 650.

First question is a stupid one but I'm still gonna ask it to avoid later worries, is there any way to install the selector forks wrong in the selector drum? Or is there only one way? The installation went smooth, didn't force anything, everything kinda fell in its place, so i suspect it's ok, but just asking to be sure.

The manual states that I should put the flat ended pin on the selector drum towards the front to find neutral, but stupid me, i have removed the pins without marking the holes. Is there a trick to easily find neutral now, or will it be trial and error to find the right position for the drum?

Or am I missing something and is this much more simple than I think?

Thanks in advance, Christof.
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May 21st, 2007, 12:05 PM   #2
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RE: Gear selector drum

Yes, this is more simple than you think. Turn the drum til you reach 1st gear (check the ratio looking at the drive shaft, if you're uncertain), next upcoming neutral is the correct one! Install the position star accordingly.

Good luck!
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May 21st, 2007, 02:22 PM   #3
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RE: Gear selector drum

agree with doctor C.

can'tget the forks wrong. you must turn the gearbox over and change gears etc. when you get to the end you should click back for neutral. now fit the star and try it again. use lots of rotation in the gearbox shafts to help the selection procedure to run itself through.

remember that you must kick up on the wheel (CW) for it to be the same as kicking down through the gearbox to first gear!

regards

Taffy
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May 22nd, 2007, 09:07 AM   #4
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Thanks for the tip! So I installed the star and all the rest of the gear shift mechanism randomly, then searched for Neutral, and then reposioned the star correctly for neutral.

Problem now is that I can easily shift to 1st gear, then up to neutral, but then I can't reach second gear.
I added some pics, the first pic is when it's in neutral, second pic is when it's in first, and the third pic is what happens if I try to get it in second gear.
It seems that the selection gear is at the en of it's movement, can this somehow be adjusted? Or am I once again missing something obvious and is there a simpler solution?

Could it be that the source of my problem is that I haven't installed the ignition side of the crank case yet?

Regards, Christof

neutral


1st gear


Attempting 2nd gear
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May 22nd, 2007, 09:20 AM   #5
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Sure you're not in between 5th and 6th gear?
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May 22nd, 2007, 10:07 AM   #6
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you won't get a proper throw until you get the 'tightness' of having the sidecover and the other half of the case fitted. all the slackness does is one thing: detract from the throw of the selector mechanism.

i can see from the photos that you are doing things correctly.

one more thing to double check however....

when in neutral you should be able to hold the imput shaft whilst spinning the output shaft.

belts and braces as we would say!

regards

Taffy
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May 22nd, 2007, 11:36 AM   #7
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I'm pretty sure I'm in neutral, I can spin the output shaft freely when I hold the input shaft still.
Also downshifting form first is impossible and feels right, if you know what I mean, but when I try to upshift to second gear, you can feel there is something wrong, so I don't think i'm inbetween 5 & 6 because then it should be the other way around.

Taffy, I'll put the cases back together tomorrow and hope for the best!
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May 22nd, 2007, 03:43 PM   #8
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You will have to turn the shafts to get a gear change or the dogs won't line up!
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May 24th, 2007, 10:48 AM   #9
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Originally Posted by coronaberg
You will have to turn the shafts to get a gear change or the dogs won't line up!
What exactly do you mean with the dogs don't line up? English is not my first language and I don't understand, sorry.

Taffy, got the cases together and put the clutch cover on for testing, but still doesn't want to shift. I'm turning the output shaft by hand when I try to shift but doesn't work.

Anybody have an Idea of what I'm doing wrong?
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May 24th, 2007, 11:11 AM   #10
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what jeff means is that as you slide two gears sideways to meet each other (on the same shaft) they will be turning at roughly the same speed. it may take a full turn of both shafts to allow the side teeth (known as the dogs) to intermesh.

i think you have put the star washer on in the wrong place. you need to go back to the star and remove, then turn the gearbox using your finger tips. neutral is somewhere else altogether. the washer will move around although i believe i have a tip for this in the owners doc under 'rebuilding the engine'. can't remember what it was - something about noting it as you strip the engine probably!

try again!

regards

Taffy
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