500 ride again project

[Nurse Julie]

What can I say, I still have loads of parts in the loft

Good thing you do Ken. I know many people would have been at a loss without your roof top Parts Department full of rare parts 👍👍👍

[Bryanj]

Trigger, having a bad day mate, still awaiting DVLA extrication of finger!

[Trigger]

Trigger, having a bad day mate, still awaiting DVLA extrication of finger!

At least it is only the finger mate, it's when you have the DVLA thumb you have problems 

[Safo]

Well that's brilliant, thanks, will get the missus on to go on ebay tomorrow, and if oddjob will part wi the bits yes I am interested, by the way if anyone is going to the winter classic show at Newark this weekend I will be on the crmc racing club stand
Thanks again

[Bryanj]

One thing to check that i just thought of is that when the shafts are in the case do any have excess movement along the shaft as there are several washers in there that could possibly break(even if i havent seen it) and/or been misplaced or lost on a previous stripdown.

[Safo]

The only gear with any excessive play is the 1st gear on the layshaft, all others (the fixed ones) seem to have their respective circlips and washers and feel ok.
Selector forks ordered from ebay
Looking for 4th gear L/S and L/S gear
HAPPY NEW YEAR!

[Bryanj]

I cant remember which gear but there is one that must be fitted with its mating gear on the other shaft as the tooth profile was changed in production. The only way i found out was when i tried to get one decades ago and was told it was superceeded and came as a pair. Sorry cant be more help

[Bryanj]

Isnt it 4th you move to lock up 3rd?

[Safo]

OK, thanks for the tips Bryanj and yes that's correct after studying things when you shift to 3rd the right selector moves the 4th gear on the layshaft into what is just called a layshaft gear via the dogs which then connects it to the mainshaft for 3rd

[Safo]

OK, oddjob I stand corrected on my terminology as I got it from  the Haynes manual, already paid for the selectors, they should be here next week, if they are no good it's £60 down the drain, and I may have to shelve the project untill I get all the bits we need,
The bike was last used in 95 up until then the oil and filter were changed at the latest every 2000m, but l don't think we ever did that much in any one Yr
must admit there was, still is a film of black crudd in the bottom of the sump. How much would you want for the centre fork?
Thanks

[Trigger]

Those doggies ( Forks) look pretty good to me Oddjob. I think you have been looking at too many NOS parts for too long 

[K2-K6]

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[Safo]

If they are like that when they arrive, think I will be happy cos they look 10 times better than whats in there now

[Safo]

I see what you mean oddjob, you mentioned drum out of line?

[matthewmosse]

I have a cb500/4 that has this issue on 1st and 2nd, what I am wondering is what is the possibility of getting the forks built up with weld - grinding back to profile and re case hardening them... we case hardened tools in collage but were working to much looser tolerances of 1/4 mm. That's obviously way too crude for an engine. I'm kind of curious to know if anyone here has experience of a engineering shop and could offer insight into how they avoid oxidation losses of the steel when heating during case hardening, plus distortion - barring those factors it's something one might attempt at home, given a kiln and accurate pyrometer, plus a lathe / mill. A bit of a skill stretch for me but most of the kit is here and a dead selector fork is dead, no harm in trying to fix it, rather more of an issue is the groove thr fork runs in on the gear, that I imagine is rather harder to re machine. The dogs seem less prone to wear and rather harder to repair / higher risk. I guess the groove could be ground smooth at an oversize and the forks built up a bit to match..... Thinking long term here, supplies of new bits running out, good used bits likewise. My bike got well past 200,000 miles before the box succumbed, others might not last so long. I would think getting new bits made would be prohibitive cost wise.