Tranny help

sporty982000

sporty982000

New Member
Jul 10, 2012
762
11
0
Illinois
Hay guys.

Good news, that JB weld, is holding. lol.

starts right up on 1st or 2nd kicks. been just throttle breaking it in, heat cycling.

why--

um wont go into gear. I here clicks, but not moving.


And I was hoping someone, can tell me where to look .


I did replace the clutch boss and wondering if I need to adjust, if the clutch is just staying engaged ?

the clutch lever pulls really easy.

So I had this thing, all part. So I am wondering if I missed something or if it might just be the clutch i need to adjust, to tight ?


Sporty
 
alright, a little more background might help here. Did this engine come completely apart (split cases) or just the clutch side cover come off?

Have you downloaded the service manual stickied in the "general support" section of the forum? Do you have a Haynes or similar?
 
the back ground was mentioned in my introduction. So I didnt think to re type it all.

Yes, have manual.

Engine came top end blown, I rebuilt top end. then found damage to cases, took apart, repaired cases. I broke the clutch boss, while taking the motor apart.

I got new clutch boss today, I put the motor all together the other day.

when i took it apart, I made sure I got the tranny gears right.

I can hear it click and engage into the gears. but im not moving. lol.

the clutch lever pulls easy.

I do know that it did go into gear before I took it apart. but now it does not.

not sure what I missed or might have re-assemble wrong. or if the clutch when i put it back together, is to to tight and engaged all the time.
 
Last edited:
Now I remember the details. I don't remember each persons particular situation,skill level, and current condition by heart :p

Is the clutch lever TOO easy to pull in? like it's touching nothing but the light little spring on the clutch arm? Did you reinstall the ball bearing in between the two pushrods when you put them together?

Did you run through the gear change mechanism IMMEDIATELY after you put the two case halves together while turning the input shaft? Did it click through then?
 
Ya, looked no ball bearing.

and no I didnt check that before putting the cases back together.

what size ball bearing I need ? dont see it in the manual. must have been missing when I got it.

I may have mentioned in another post. I noticed the balancer gear was wrong taking it apart.

So someone has been there before me, must have lost that bearing.

Either way, looks like ill be taking it back apart.

Sporty


But thanks, you asked the two things I didnt dew or check. so thanks.

Sporty
 
dang missed it in the manual it was on page 4-40

but dont say what size.

as for the tranny, thats nto my strong area either.

I know I got the shift cam and forks in right spot. or atleast i thought I did.

any idea, where to look there ? on what I did wrong.
 
did you align the dots on the inner basket and pressure plate ???
can you physically see the clutch plates touching ???
maybe pick at them with a screwdriver to see if they are loose in the basket, they should be held tight by the pressure plate and not move.

sounds like a clutch problem not a tranny problem ???
will it shift up and down thru all 6 gears ???
 
From what I can tell, it is shifting fine, just not engaged.

Yes, you are right, the clutch plates were loose, even with the spring torqed to 4.3 pounds.


man that would be awesome, if I didnt have to split the cases again and hay. I found a 3/16th ball bearing, chrome polished, and hardened. Diggin thru stuff in my junk. lol.

So I will try this tommarow

Thanks 4 your help.

Sporty
 
sounds like you don't have the 2 dots aligned as i show in my DIY thread posted above

or not enuf plates and fibers in there ???
 
Last edited:
well once I put that ball bearing in there. I can check also, plates and fibers, I took out what was in there and put it all back. unless someone before me left it out, like they did the ball bearing.

how many plates and fibers ?
 
8 fibers and 7 plates, from the back it starts..... fiber/plate/fiber/plate ect. ect. ending with a fiber
 
I believe there are 7 fibers and 6 steels.

Good point out Awk, if the two embossed dots are not aligned on the inner basket and pressure plate it won't engine the clutch and the input shaft may not be turning. Without the input shaft having some turning tension on it, a sequential transmission can try to shift "dog against dog" and won't ever go into the gear.

Edit: 8 and 7? hmmmm been a while since I've counted them but sounds gewd!
 
sicivicdude said:
I believe there are 7 fibers and 6 steels.


Edit: 8 and 7? hmmmm been a while since I've counted them but sounds gewd!
Click to expand...

i only counted the fibers shown in that DIY basket install i posted above, and now that i think about it, driveline i believe gave me the thin one, and a replacement full size, i may have counted them both ???

anyone know for sure, now that i confused si ???
LOL

EDIT....INDEED I DID COUNT THE EXTRA THIN FIBER
7 FIBERS AND 6 STEELS IS CORRECT
 
AHHHHHHHHH ! I'm confused!

There is one more fiber than there is steel because a fiber sits against the inner hub and pressure plate (the outside two) but for some reason the numbers 7 and 6 were sticking in my head.

It's completely possible that it's 8 and 7 and it's just been that long since I actually sat down and took my gloves and socks off to count! BWAHAHAH! Not sure why it takes fingers AND toes to count to 8 but some people, you know!

I guess I could go look at that service manual or parts diagram but the important part is not to skip any and fill the clutch cavity up so that when the springs are in place, the clutch pack isn't loose!
 
Ya, I know I got one goofy one. more like a thing type metal band spring. I can count mine.

But did some searching with the search engine and seen several different answers. so confused me.

Can't thank you all enough, tranny and clutch are not my strong suite. so Amen and thank u.

Sporty
 
The one goofy one is called the "wave" ring clutch fiber. That's there *supposedly* to ease the clutch and shifting in to make it easier for novice riders. The higher upgraded clutches (driveline HD or 240HD) have one goofy one and an additional full size one (like the others) so you can take the goofy one out if you please. I have done so and except for some sticking when I first crank it up after it's been sitting for a while, I've noticed no ill effects.
 
I went and counted 8 fibers. and I didnt count the plates. but looks to be 6 or 7 there.

So perhaps the bearing, not being there, caused all this, will find out soon, either i will work in the night outside with some lights or wait till morning. i dont have a garage. lol


and ill make sure the dots are right. So ill post back when I got that all done and see what I run into.

Which this would be great if this is all that it is. splitting the cases again, not wanting to do that just yet again.
Sporty
 
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