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5th gear problem???

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Johnny4428:
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!

paul G:

--- Quote from: Johnny4428 on April 26, 2022, 08:24:57 AM ---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!

--- End quote ---
You can split the cases with the head and barrels in place  ;)

paul G:
Is this any help to you from over the pond but quite comprehensive and Hondaman is involved in the thread.

http://forums.sohc4.net/index.php/topic,138663.0.html

K2-K6:

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The manual picture may help you.

The last two images of 4th then fith gear selected show the gear moved into contact to get those two. Right for dog engagement, left for gear teeth engagement and quite a long throw for the selector fork to get from one to other. I always think it's the most imprecise shift in that box, and got to be certain you move it competently to be clean.

If the gear teeth on the smaller gear (going inside that far left cog) have any significant rounded noses to the teeth it can easily push it back out again under torque. 

Johnny4428:
Thanks for the info and pictures guys. Holy that’s quite a read Paul. A lot of stuff to digest, I have enough info to try one or two small things before I go in head first. I am now very intrigued myself to find out what the problem is. That’s a very handy diagram with the gear positions to help visualise possible problems.

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