I wonder if …

[Swiss Toni]

I don’t know if any of you have a carry-on when assembling crankcases together. Trying to get the selector forks in the right grooves, trying to push them into place while one handedly holding the cases apart, all the time bearing in mind, the sealant is ‘going off’?

Well. I wondered if it could be made easier?

What I did was, remove the gear change shaft, (no need to pull it out completely, just disengage it from the selector drum pinion). Remove the selector fork shaft lock plate, shaft and selector forks Drop the forks into their correct position, in the upper case clusters. Put the cases together. Then, it’s a simple matter of lining up the forks, through the sump, from right to left individually, and sliding the shaft in gently, remembering to place the selector drum in the neutral position.  

Ten times easier (for me, at least).

Edited April 16, 2023 by Swiss Toni

[TonyGee]

good idea Toni 

[TLRS]

8 hours ago, Swiss Toni said:

..and sliding the shaft in gently. 

You been listening to your better half there haven't you..

[Duckndive]

I,ve cable tied the box into the bottom case and then fitted it onto the top in the past   

Edited March 16, 2023 by Duckndive

[TLRS]

When I'm putting forks together I like to keep the finish nice. And yokes tend to be tight. What I do is block the groove. Then screw a bolt in from the wrong end (yoke permitting) and gently push against that blockage. This way the yoke can be opened ever so slightly. This makes it much easier to install the leg. Keep it tight enough and it'll still hold the leg when you run of for beer/tea/tools etc.

Obviously if you overdo it then pang, yoke ruined. So be warned y'all.

[Swiss Toni]

And, although you have 2 selector shafts to play with, I can’t see why this won’t work on the aircooled’s. 

[Swiss Toni]

38 minutes ago, Duckndive said:

I,ve cable tied the box into the bottom case and then fitted it onto the top in the past   

Was it not a nightmare trying to locate the bearing half rings and location pegs?

Edited March 16, 2023 by Swiss Toni

[Duckndive]

Just now, Swiss Toni said:

Was it not a nightmare trying to locate the half rings and location pegs?

less of a fiddle than selector forks and no damaged fingers