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Just a thought Gary, the selector drum that positions these forks when the gears are selected could also be worn and make a difference. Also the levers that rotate the drum.
Fork looks bent sideways, only supposed to touch on either side of the two pads out at end of fork.Looks like a half moon witness mark at base of semi circle that's been rubbing where it shouldn't. That will probably account for the error you're seeing in travel.
Quote from: K2-K6 on October 05, 2023, 09:45:01 PMFork looks bent sideways, only supposed to touch on either side of the two pads out at end of fork.Looks like a half moon witness mark at base of semi circle that's been rubbing where it shouldn't. That will probably account for the error you're seeing in travel.I thought the fork might be bent, but if it is I cant discern it. Def worn at base which makes me think the pads are shot.
I like to see pics of the gear dogs concerned, also does the gear dogs move more into the mating gear with selectors out.2 does it look like its been apart before?
Quote from: gary123 on October 05, 2023, 10:38:45 PMQuote from: K2-K6 on October 05, 2023, 09:45:01 PMFork looks bent sideways, only supposed to touch on either side of the two pads out at end of fork.Looks like a half moon witness mark at base of semi circle that's been rubbing where it shouldn't. That will probably account for the error you're seeing in travel.I thought the fork might be bent, but if it is I cant discern it. Def worn at base which makes me think the pads are shot.I can't see complete detail from photo as slight blurr on fork of second one, but the pad looks more worn nearer the inner edge. If the other side (not in photos) of the pad has the tips more worn, giving a "diagonal" opposed wear pattern to the pads ? Then the alignment of them is contrary to the gear slot such that it siits touching both sides from that fault. Slightly difficult to explain, but hope that makes sense. Also usually shows with some heat blueing from running in contact continuously on some examples. That burr around the half moon cut shows quite a bit of running contact has taken place, when it shouldn't touch there at all.
That's probably why it happened Gary. The circlips used on the gearbox are special, they are not eared like your picture, they are shouldered as well, so they fit in one direction. I seem to recall this makes them thinner than standard circlips. Look like this.https://www.cmsnl.com/honda-cb550f1-super-sport-550-four-1976-england_model17113/set-ring25mm_90602259010/