Reaching out for reassurance

[Mannyroad]

Hi guys,
Well, today reached one of those moments when your heart stops, in panic, so I'm reaching out to you guys who've done a complete motor rebuild in the hope you're gonna tell me "don't worry".
So, I'm in the final stages of the new chop build, almost a fully built bike with just the electrics to sort out. Decided to fit the drive chain, one of the last items to fit other than tank, seat and complete the electrics. Then came the heart stopping moment - I can't find neutral, so I can feed the 530 chain over the front sprocket. Tried turning crank over while shifting and also just rocking the gearbox sprocket back and forth while shifting, but no matter what I can't get a freely turning sprocket. I can go what feels like up through all the gears and back down again, but just no neutral. My huge worry, at this final stage is that I have to pull the whole bike apart again to get the motor out and then strip the motor back apart. If that's the case I will feel like throwing a sheet over it and sacking it off for this season.

When I stripped the motor the input and output shaft were just lifted out and later re-inserted whole and the selector forks also went back in all as they should. Its such a simple gearbox setup I find it hard to think I've gone wrong.

So, am I panicking over nothing?

 

[Downeaster]

So, am I panicking over nothing?

Probably. Three reasons:

1. Neutral is a "half click" above 1st and can be finicky to find without the motor running.
2. It may be that your "shift star" needs to be adjusted/aligned with the linkage. Is it finding all the gears and clicking in positively?
3. It may be necessary to hold the clutch lever down to free up the trans enough to find neutral.

 

[GLJ]

Did you make sure you have the neutral detent installed correctly?

 

[Mannyroad]

At the moment the engine has no oil in it and all the moving parts have been coated with Graphogen to help out at start up. No clutch lever in place yet. I have another XS and a TX so am well versed in the difficulties of finding neutral, so because I'm still struggling I figured I'd missed something in the rebuild.

However, I took the indent plunger out and used the shifter to line up the indent, then re-inserted the plunger and spring and suddenly there was no issues with finding neutral. But I can't understand what I did to make a difference. Surely the plunger was always going to find the indent. Unless maybe (though I can't think why) the plunger spring was failing to push the plunger down firmly. I'm a retired engineer, so it irritates me to accept a solved problem without understanding the cause. Thanks for your contributions guys.

 

[Signal]

Here is a theory to ponder. The detent housing in the case has a generous clearance to part #19.
I think it is possible if the detent was installed without oil part #19 it could bind in the case and not be able to make contact with the selector drum.

 

[Mannyroad]

Ok, makes sense, though used Lubriplate 105 assembly lube.

 

[Wingedwheel]

When the solution can’t be explained from an engineering viewpoint it’s useful to say when you installed the plunger originally you didn’t hold your mouth right…

 

[Mannyroad]

Yes, it is a bit of a mystery why simply removing the plunger (lubed) aligning the detent, then re-installing the plunger, changed anything. Come to think of it, I may have been grimacingvat the time, so I reckon you're right about the mouth thing. Will remember to keep smilingvat all times, so as to emit positive waves

 

[Grimly]

When the solution can’t be explained from an engineering viewpoint it’s useful to say when you installed the plunger originally you didn’t hold your mouth right…

Yep. Chewing the tongue with the left molars is best.