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This is not good! After doing just over 100 odd miles or so after rebuild without any serious hitches I was feeling quite good about the running and handling of the bike, that is until coming back from a run a few days ago 5th gear didn’t engage properly until the third or fourth attempt. I thought that’s strange hasn’t done that before. I have removed cover and had a look but couldn’t see any problems with selector mech. Seems to change into every gear no problem spinning back wheel. But out on the road this seems to be happening every time. I don’t like the crunch of one gear spinning against the other without engaging so I’m reluctant to go out again until I get to the bottom of the problem. I’m fearing the worst which is that this is not going to be sorted from the outside of the gearbox.😡
Thanks guys for your input much appreciated. I have had the bike up on the lift going through the gears and it seems to be doing what it is supposed to do engaging all the gears so I suppose it must be spitting 5th gear out. I haven’t been back out for a run to try changing gear 4 to 5th without clutch. I didn’t have the gears stripped from shafts completely but I did have some off as I replaced worn bushes and bearings. So at this stage I wouldn’t rule out the possibility Paul. I think I’m “going to do what a man’s got to do” . Good job it’s not nice riding weather!
You can not go by any manual when it comes to the 750 gear box as Paul found out. The manual will not show all the washers and which way they go round. Some of the very early boxes had extra shims.The big mistake owner make is not locating the natural switch. Before you put any cogs in put the selector drum in and then the natural switch. I will let Paul own up to the mistakes he made with going by the manual