Slow engine rebuild progressing,however!

[Greg65]

With weekly commuting and shift work my engine rebuild has been slower than desired however I now have it in the frame. So before attaching the remaining bits I thought I ought to test the gears before I go any further so I attached the sprocket and chain. First up I have no neutral and can not select first gear while manually turning the engine over. The cam is in the indent on the gear shift drum. From this position I can not select first however can shift up.

So what am I missing or need to check? Advice would be appreciated.

Thanks,
Greg

[Greg65]

Picture.

[K2-K6]

Ordinarily you can remove the clutch to see what's going on,  also you don't then have to turn the engine to rotate the gearbox in testing functionality, just spin the clutch to gearbox driveshaft to work through the gearshift.

May help you see if anything selector wise is odd.

[Bryanj]

To run through the gears you notmaly have to §pin both shafts. 1st can be a bit of a bugger on new build at standstill but should go in if shaft rotated.

[Nurse Julie]

Did you take the gearbox apart Greg?

[Nurse Julie]

And do all your bits look assembled like this?
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[Greg65]

Gear box dismantled, hope to sneak out and remove clutch and compare shortly.

Thanks all, Greg

[Greg65]

Clutch removed and can’t see any obvious error. Here’s mine.

[Nurse Julie]

Ok. Can you spin both shafts and get the gears in the correct position where you can see the brass connector through where the neutral switch inserts. This will give you a neutral reference point.

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[Greg65]

Have been reassigned to BBQ duties, will look tomorrow.

Thanks to all,
Greg

[Lobo]

Greg; you describe exactly the situation when I returned my restored engine to the frame. I rang the engine builder in a bit of a huff, he was nonplussed and ‘guaranteed’ his work; and suggested to simply proceed and that once oil was put in the engine / ‘box and circulated all would be fine.
And indeed it was.

Not saying that this is your issue, but if you can’t find an answer then all may still be ok.

Simon

[Greg65]

Thanks for your reassuring words Lobo however as this is my first rebuild I come with no guarantees. I hope my situation is the same as yours but I question myself as I have caught 3 minor mistakes during the assembly through checking and doubting. I have really enjoyed the process, especially the diy zinc plating, it’s just the final bit has some nasty consequences if there is an error. Just need some workshop time to go through the checks suggested.

Cheers,
Greg

[Greg65]

Workshop update.

With the neutral switch removed, brass connector visible, the bike is in a gear. Selecting down achieves nothing. Shifting up once, twice both result in the gears locking. Shifting up a third time produces a gear, up again it locks and up once more finds a gear. No neutral located.

So my guess is that I have got the left and right selector forks in their opposite positions. So engine out and as I understand from Haynes I can leave the head attached and just split the case, then rebuild correctly.

Any other conclusions or suggestions to try would be appreciated.

Thanks,
Greg

[Nurse Julie]

Mmmm, sounds like your assumption is correct Greg. Yes, you can do it just by splitting the bottom cases. Onwards and upwards, us novices are allowed to make mistakes 👍👍👍👍

[Greg65]

Julie.

Thanks for your kind words and encouragement, Oi stop sniggering at the back.

Cheers,
Greg