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gearbox jumping out of gear

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parky955

Joined Apr 2009
9 Posts | 0+
Hi fellas, need some advice on this problem. Have just completed rebuilding my motor and refitted to bike, all is good apart from it jumping out of gear, first gear is fine but hook second and as soon as the power comes on it neutralises, no clonk bang nothing just smoothly slips out of gear. Have had side cover off, selector mechanism is fine so my question is this, what could it be internally? Bike never done it before and when I took it apart the two shafts from the gearbox were left intact, didn't remove anything off them just stored them safely until I put it back together. Everything went together sweet, no problems at all. Can the selector forks be fitted in the wrong place at all? As you can imagine I really don't want to strip it again having only just got it all back together so any advice would be great thanks guys

Cheers Jon
P.S its a 2000 FC501
 
No need for anything to be wrong for it to happen on the 2000.
The clutch cover sticks out a bit and the gaer changer must subsequently stick out even more. That's what you get when the clutch is on the left side, the Husqvarna heritage. The inside of the boot can easiliy slip the gear down from 2nd to neutral or from any higher gear to false neutral or to next lower gear. Especially if the lever is in a high position to clear it from deep ruts and high stones and such. Newer levers are slightly better than the older straight ones because the newer are routed differently.
But if it is power coming on that kicks out the gear I have no idea.
Regards.
 
It is definitly the power coming on that makes it happen, wish it was as simple as my boot hitting it out! That would be an easy fix!
 
the selector mechanism seems to be at fault. undo the cover and get the clutch off then take the selector fork off. it's not "driving through the changes" it's only half pushing the drum around. your mission is to see why!

you have burring to find, springs that have stretched or got trapped, the selector star is misplaced....do you have all 6 gears working normally?

regards

Taffy
 
Yes all 6 gears are selectable, have had the cover and clutch off already, the selector seems ok to me, cleaned up some minor burrs on it before I put it all back together. Could the gap between the jaws that click the drum around be at fault? I guess if they have worn at the very ends they may not be turning the drum quite enough maybe, looks ok though. You don't think it could be something internal?

Thanks for your help Taffy
 
did you check the central post? they are always coming loose?

i was always kicking mine into neutral accidentally as has been mentioned. for ages i was saying; "i's not me!" - but it was! i can't tell you how many times i nearly went over the bars.

regards

Taffy
 
Checked the central bolt, had heard that they were prone to coming loose but made sure it was tight and threadlocked when I put it back together, have had the cover and clutch off again but I cannot see anything that would be causing this to happen so am thinking its going to have to be pulled apart again for a look inside. Any ideas what it could be internally?
 
not now no. if you swear blind that a gear never came off then there shouldn't be anything wrong! perhaps the selsctor ring came off the selector fork.

regards

Taffy
 
By that you mean the wee sleeve piece on the fork that runs in the grooves on the selector drum? That could be possible I guess, may have come off while putting the cases together. I agree that there shouldn't be anything else, as I said earlier the two gear assemblies where never dismantled, just removed them both as a unit and had them stored in an old lunchbox for safe keeping, then took them out and put them straight back in when I put it back together. Very frustrating but half the fun is fixing them huh! Thanks for the advice mate, think I'll strip the engine again for a look, have checked the selector side of things enough times now to know its not causing the problem. I'll let you know what I find.

Cheers Jon
 
parky955 said:
By that you mean the wee sleeve piece on the fork that runs in the grooves on the selector drum? That could be possible I guess, may have come off while putting the cases together. I agree that there shouldn't be anything else, as I said earlier the two gear assemblies where never dismantled, just removed them both as a unit and had them stored in an old lunchbox for safe keeping, then took them out and put them straight back in when I put it back together. Very frustrating but half the fun is fixing them huh! Thanks for the advice mate, think I'll strip the engine again for a look, have checked the selector side of things enough times now to know its not causing the problem. I'll let you know what I find.

Cheers Jon
Click to expand...

does sound like you maybe may have lost a shim on the end of one of the shafts. easy to fumble it. bob
 
I would guess that a spacer shim was left out that goes on one end of a gear shaft. When that is done, it effectively moves the gears over about 1.5mm. this in relation to the shift forks. In one direction, you will get too much engagement of the shift dogs, in the other, too little. Just a guess.
 
the shift fork collar see if its on the magnetic plug ? or the shed floor.

either way fix it quick dem gears is expensive :(
 
OK so got engine stripped now, was hoping to find one of the shift fork collars in the bottom of the case but no, all 3 are in the correct place! Dam! Everything looks sweet, can someone tell me the correct positioning for the shift drum?
 
from here i find it difficult to say.

i would put it all together less the crank assembly and turn the selector drum without the star even being fitted. turn it clockwise till it was is in first, back slightly MUST BE NEUTRAL. do both shafts spin independantly? if so this is neutral and mark THAT PIN. NOW.

i don't think you really had the right neutral point on the drum.

regards

Taffy
 
Thanks Taffy, so it would be possible to have the neutral point wrong? that was what i was thinking too, ran out of time tonight after splitting the cases to investigate further but with everything else looking ok it can't be too much else. Will have a play around with it tomorrow night and will keep ya's posted.

jon
 
Hi guys, well no luck, found correct nuetral point on drum, checked everything else, all looks good, reassembled and still doing the same thing!! Even lots of swearing didn't seem to help ( think my neighbour got a bit worried tho...) So, still selects first gear no prob then nothing after that, if you hold the gear lever up when hooking second gear theres some pretty ugly noises going on inside, sounds like the gears aren't engaging at all after first but are just rubbing together on the sides of the teeth...
 
get it apwart and send the box to a pro. that in itself would be a reasonable cost. you then get it back strapped up tight and ready to refit.

that's all i can think of....

regards

Taffy
 
Yep think thats gunna have to be my next move, dam I hate admitting defeat... Thanks for all the advice anyway

Cheers jon
 
Speaking from experience here, when I disassembled my engine, I took the star of the selector drum without marking neutral, boy did I ever regret that.

I've had to put together and split my engine 5 times before I found the correct position of the star in relation to the drum. It would work perfectly when I had 1 half with the gearbox in, I could select all six gears plus neutral, but as soon as I put on the second engine case and torqued everything down it stopped working properly.

So my guess is also that there is something wrong with the position of the star, I would also take the crank out and try all 6 positions on the star, there is only on correct one, if your lucky you might have it right on the first try, took me 5 tries to get it right :)

The symptoms you describe are very much like the ones I had when I had assembled the engine with the star in the wrong position, first was ok, 2nd you kinda could feel it wanting to shift gear but not engaging fully.
 
the gearbox drum is one up and five down. you should take the star off and turn the drum right to the end and then back one. the gearbox will only be five and one or one and five. it's the neutral you are moving with the star. just get neutral in the box which is one from the end whatever happens THEN add the star

regards

Taffy
 

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