Gearbox Stuck - The last straw?

[Laverda Dave]

OK, thanks.

I'll try that once I get the clutch off. Trying to find someone with a castellated socket; I'm here with 4 spanners, a screwdriver and a vise grip! 

You need the correct tool to remove the clutch centre nut, it is held on really tight. You'll need to probably use a torque ratchet to get the oomph needed to loosen it and make sure you have bent the tabs back on the lock washer before attempting to undo the nut (and replace the tab washer, not worth the risk of using the old one).

[SeanFD]

I've got the clutch off now - had to hire an impact wrench to remove the centre nut!

The only thing that looked amiss in the selector setup was the actuator to the end of the gear shaft; it seemed to have moved outwards and was not meshing with the pins on the drum centre.

With everything off, it looks to me as if the selector drum, when the gearbox is in "neutral" that the hole to align with the drum centre is rotated too far anti-clockwise?

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I can move the drum only about 30º and there is a positive and solid click each time it moves - I replaced the bits on the end of the drum to allow me to rotate it. It will only go anti-clockwise and I've no way of telling if different gears are actually being selected.

What next? The only thing I can think, is reassemble and see f it works!

Not feeling too hopeful here! 

[K2-K6]

You should be able to feel the difference in ratio by turning the rear wheel, it will rotate the centre (clutch) shaft at different speed.

1st would spin that shaft fastest, 6th the slowest.

[SeanFD]

It doesn't seem to change; at least not noticeably.

[K2-K6]

Have you got the shift mech reassembled  ?

If so, with a mark on the outer face to show movement, it should "index" around each time the lever is used. Then obviously return to original position by going back down the ratios.

[SeanFD]

Which direction does it move when going up through the gears?

I can only move things anticlockwise, 4-5 "clicks".

That reference hole on the drum doesn't move at all.

I have 2 settings:
1.  Rear wheel and shaft turn together - each one turns the other in both directions. As I said earlier, it doesn't feel like it gets easier/harder or /faster/slower as I move through those 5 clicks.

2.  Wheel and shaft are separated; each can turn independently.

[Bryanj]

It is very difficult to diagnose long distance but from what you are describing i think something is assembled wrong, at leasr you dont have to take any top end stuff off to check

[SeanFD]

She ran OK, with noting feeling wrong for a short while, so I would think it is more like something has come adrift or broken.

Anyway, I'll not be taking anything further for now; I have to go home and prepare to finish my odyssey - I still haven't heard if Iran is issuing visas again yet.

So just when I thought I could jump into the water, looks like I'll be sitting on the bank for another while; probably be Xmas before I'm back to try and finish the job.

My general philosophy: It'll be all right in the end. If it's not all right ....!

[SeanFD]

OK, so I went out this morning just to reassemble everything and put it away, but of course I couldn't just do that, could I.

I got this video once things were back together.

https://youtube.com/shorts/3N8Lcwp9agM?feature=share

It looks to me like the selector drum has rotated because that locator pin is too far anticlockwise when compared to the only other shot I could find of it on-line.

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With mine the way it is, the actuator has only two lugs to act on.

[Bryanj]

I rhink it can only do that with the gearshafts out

[SeanFD]

when I get home, I think I have more pics of the assembly. It'll be interesting to see where it was when I put it together.