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Gear selector drum (fixed!)

B

BelgiqueBasterd

Joined Oct 2006
381 Posts | 1+
Belgium
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.
 
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!
 
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
 
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
254449119.jpg


1st gear
254449197.jpg


Attempting 2nd gear
254449162.jpg
 
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
 
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!
 
coronaberg said:
You will have to turn the shafts to get a gear change or the dogs won't line up!
Click to expand...

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?
 
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
 
Got it fixed, apparantly there is a wrong way to install the selector forks, took everything apart again, put the drum and forks in a different position, and put everything back together, works like a charm now!

Thanks for everyones help!
 
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Hi,Guys,may you could help me
I have similar problem like BelgiqueBasterd had.Right now I have only two gears: first gear and neutral .I can easily shift to 1st gear,but can't reach second gear or any other higher gears.Engine is fully mounted and I would like to solve this problem without engine stripping.I think main problems is that two gears sideways on the same shaft meet each other.
Thanks.
 
so what happened? you stripped and rebuilt the engine right?

now you only get two gears?

it could well be that you fitted the selector star all wrong. undo the sidecover and go through all the gears with the selector star off. remember that it is one up of the claw for first then down for neutral and then another 5 down for top gear? you're looking for neutral.

best way is, star off, sprung wheel off then just turn by hand and keep spinning the rear wheel by hand to get the gearbox rolling a little. once you get a feel for where you are: aim for neutral. then set the star.

regards

Taffy
 
appreciated but we need to know that the selector star neutral is not just lucky!

i also noticed that with the bike in neutral at 38-40 seconds that the claw is nearer one direction than the other. that could be because neutral is in the wrong place and being dictated by the star!!!!!

regards

Taffy
 
I can't put selector star wrongly ,because there is marked neutral gear point on the drum.
Shifting was working well before I have mounted engine cases.
I think this problem started when I was moving piston.(possible not in neutral gear)
 
you can try putting a crowsfoot lever under the edge and pulling the drum up towards you.

regards

Taffy
 
Just tried,it also doesn't work.I think I have no choice right now and I will have to open gearbox again...
 
If thread author solved same problem after remounting shifting mechanism I hope so that my gearbox is also not exception.
 

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