Swiss Toni Posted November 23, 2018 Posted November 23, 2018 Doing a 'dry build' on the 1100ET motor, just to see what's there, and what's ... not! All gears & g/change paraphernalia installed in upper & lower cases. Selector forks hanging down, as per manual but, forks not lining up with tracks on gears, stopping cases coming together! They're landing on the gears! Forks won't move sideways, due to slots in selector drum. Nowhere in any of my manuals, OEM Suzuki, Haynes or Clymer does it say gearbox has to be set in a certain way, or neutral. So, 'What's the problem?' Tell me how you do it! Quote
Guest YoshiJohnny Posted November 23, 2018 Posted November 23, 2018 make sure the detent for neutral is engaged on the selector "star" make sure the forks are on the right shaft and the correct left and right the forks shouldn't move but the gears can... line them up by spinning gears to engage side to side if need be.. Quote
Duckndive Posted November 23, 2018 Posted November 23, 2018 Build the g-box in the bottom case and you will find out what the problem is.............. Fix it and then swop it to the top case and fit the bottom................ Not having the drum in neutral and indexed correctly is a common skool boy error 1 Quote
Sheep Posted November 23, 2018 Posted November 23, 2018 I experienced similar issues when putting my halves back together.The forks seemed to mismatch just as the casings came close...Turned out,after the third attempt of trying,that the larger end bearing kept getting slightly pushed out by the wavy shims just as I went to close them.Once I noticed this they went back together with a satisfying clunk. Quote
Swiss Toni Posted November 24, 2018 Author Posted November 24, 2018 Placed the shift drum in correct position. Detent plunger in neutral 'dimple' in shift drum. Forks still hitting gears. Fitted clusters into lower case yesterday, everything works and fits ok. Re-try on Monday! 65 yrs since I was a 'schoolboy' ! Quote
Sheep Posted November 30, 2018 Posted November 30, 2018 Did you find the problem Swiss Toni or was it simply the forks getting in the way? Quote
Swiss Toni Posted November 30, 2018 Author Posted November 30, 2018 As Clive & YJ said, shift drum just off the detent plunger position, and selector forks just needed sliding across to suit. All gears selecting correctly! Thanks boys! Quote
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