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Author [NL] [FR] [ES] [DE] [SE] [IT] [NO] [MY] Topic: New chain & sprockets  (Read 1411 times)

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Offline jdoyle

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Re: New chain & sprockets
« Reply #10 on: May 12, 2022, 02:08 PM »
Have hit a bit of a dead end
Gearbox is back in and the chain is on
adjusted the clutch cable
put in some fresh oil
Bike is on the paddock stand
Turned the key & neutral light comes on wheel rotates freely
Start it up and it did not burst in to flames :-)

Engine running and I can select first gear bit of a clunk but it goes in
Try second gear and wahoo second works also
Try 3rd and its like its back in neutral no drive & the wheel stops rotating
Try 4th and it wont go in just makes a bit of a grating noise so I did not want to do any damage so I stopped
Bummer
Decided to stop for lunch

Anyone care to have a guess at what could be the issue ?
Cheers
J

Offline jdoyle

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Re: New chain & sprockets
« Reply #11 on: May 14, 2022, 04:49 PM »
Spent Yesterday and Today trying to get this sorted

This morning I tried it again same thing so I thought maybe the shift rod needed a little adjustment and I spent quite a while adjusting it back and forward with no success :-(
No Matter what I did it just will not go in to any gear after 2
Thinking the replacement box was duff I took it back out
When it was out I noticed that the Locating dowels were still in the old box I had forgotten to swap them over and although I was skeptical that the dowels would make any difference I put the box back in with the dowels

Needless to say it made no difference :-(
So I took the box out again getting quicker at it now

I swapped over the good output shaft in to the old box and reinstalled and the blasted thing is the same with the old box wont go past 3rd gear
The old box was working ok other than the shaft damage so I'm thinking it must be me doing something wrong on installation as both boxes are exhibiting the exact same symptoms

Any gearbox guru's out there can point me in the right direction ?
Or any input at all is welcome at this point
I did not dismantle the selector I just removed and reinstalled it while replacing the gearbox

Offline Clunkyboy

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Re: New chain & sprockets
« Reply #12 on: May 14, 2022, 10:55 PM »
You lost me at shift rods 😅😅
Dunno what happened,  one time I would strip a Lancia delta down to its rust, now I think changing oil is a big whoo whoo. Old age is shite
MT 5, KH 100, IT 175, XR 250, GPZ 600, GPZ 900, GPZ 750, GSXr 1100, XJ 1100, XJ 1200, Super Tenere, GSX 750, 10YR Break, VERSYS Mk1,VERSYS Mk2

Offline jdoyle

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Re: New chain & sprockets
« Reply #13 on: May 15, 2022, 06:52 AM »
*Originally Posted by Clunkyboy [+]
You lost me at shift rods 😅😅
Dunno what happened,  one time I would strip a Lancia delta down to its rust, now I think changing oil is a big whoo whoo. Old age is shite
A Lancia Delta  :001: Those were the days  :001: :001:
I used to have great patience for fixing our old family cars and i was pretty good at it as we couldn't afford to get anyone else to do it 
Now at 57 years i'm just to old & senile
This issue with the gearbox seems to me to be something that I am doing wrong on assembly or installation but the manual  does not mention any specific tips or tricks
just put the gear selector drum in the Neutral position
slot the box in
put back on gear selector and the job should be oxo

Offline jdoyle

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Re: New chain & sprockets
« Reply #14 on: May 15, 2022, 12:06 PM »
Been out tinkering with the bike

Took it off the paddock stand to try bring it for a run 

I was checking the adjustment of the clutch by putting it in to first gear pulling in the clutch in and pushing the bike to see if the clutch was releasing and to my surprise it did not 

The clutch lever and the clutch actuating arm on the clutch cover seem to be operating normally and I had oiled the cable and the cable is about a year old and moves freely and seems to be in good condition 

I can feel resistance against the spring but it was like it was not doing anything the drive still seemed to be engaged

So I started to adjust the clutch more to try get it to the point where the drive to the wheel was disengaged 

several turns later the back wheel started to turn while pushing in gear but there was no drive to the wheel when in gear & the clutch was released with the engine running

In order to get drive to the wheel I had to slacken off the adjustment but then pulling the clutch in while in gear did not appear to to release the drive to the wheel 



Sorry about the long posts but this is doing my head in 



Could this be why it wont go in to gear above third and not a gearbox problem at all?

Or is that wishful thinking 

J

Offline jdoyle

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Re: New chain & sprockets
« Reply #15 on: May 18, 2022, 07:36 PM »
The issue was definitely the replacement box as with the clutch and basket the drum would not rotate past 3rd gear

I removed the box again ( getting to be an expert at it now ) and removed the output shaft and put the old damaged one back and reinstalled the box and other than the original damaged splines it is working Ok cycles through the gears by spinning the drive shaft by hand while turning the drum

I have buttoned it back up & refilled the oil

Started it up and runs and goes through the gears on the paddock stand

If the weather co operates I might get it out for a little run later

Offline Clunkyboy

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Re: New chain & sprockets
« Reply #16 on: May 19, 2022, 07:16 AM »
 :152: :152: :152:
MT 5, KH 100, IT 175, XR 250, GPZ 600, GPZ 900, GPZ 750, GSXr 1100, XJ 1100, XJ 1200, Super Tenere, GSX 750, 10YR Break, VERSYS Mk1,VERSYS Mk2

Offline Imightbewrong202

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Re: New chain & sprockets
« Reply #17 on: May 19, 2022, 08:11 AM »
Well done!
How many times did you have to drain and fill the oil now?

I'm only following parts of what you're explaining as my technical knowledge doesn't reach so far yet.. but did you fix the initial issue?

Offline jdoyle

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Re: New chain & sprockets
« Reply #18 on: May 19, 2022, 02:59 PM »
*Originally Posted by Imightbewrong202 [+]
Well done!
How many times did you have to drain and fill the oil now?

I'm only following parts of what you're explaining as my technical knowledge doesn't reach so far yet.. but did you fix the initial issue?
I Think 3 times I put oil in
Rest of the tinkering I was trying to get the drum to rotate while turning the input shaft by hand
 

I did not get the replacement gearbox to work and had to put the old one back