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[Super45]

So some of you may read on the MBR forum that on my 2000 350 ive curently got a cracked inner and outer primary case as the clutch centre nut hadnt been tighteded correctly and neither had the 3 clutch spring bolts which had made a bid for freedome gouging a grove in the outter case so appologies for the repitition if youve alread read this.

clutch was noisey and handnt run the bike asince i notices this and at same time seemd to loose some gears like 1st and second, this was some weeks ago and when i removed the bike from garage over weekend the gears seemd to of reappeard just from leaving the bike standing which is very strange

so clutch strip occured sunday, found plates in slightly wrong order so will be correcting that

gave the clutch rod a bit of grease and rebuilt it

then decided to ( rightly or wrongly ( to investgate under the gearbox end cover, all levers and washers positions noted and stiped off to have a butchers inside at the mechanisms,

clutch arm and bearing stipped cleaned and greased as there had obviously been some water down though the casing hole at some point couldnt see much else to fiddle with ( sides noting the gearlever play as mentioned in my other forum post seems to stem from what seems to be play in the bearings underneath the shaft spline but not sure if is normal) so I rebuilt the casing with extra dab of grease on the clutch arm ball where it meets the pushrod for good measure

Rebuilt the outter casing and this is where thw trouble started...

every lever and bolt went back in the same place ( even the neutral finder adjuster cam I left the dirty mark on where it was previsouly so was able to put it back exactly )

but despite cylicng easily through the gears by hand as it was removed out of the garaage after removing the casing and the clutch strip I seemed to have lost 4th( According to the neutral finder as it wont point to 4th ) and some other gears were a lot more dificult to select, I double checked my lever positions and they were exactly as I left them amnd even kikced the bike over incase it ws just in the wrong position within the box to be able to select but still no change or with clutch in or out

so does it sound like?

A) the clutch needs to be rebuilt in correct order ( 2 plates n wrong place according to diagrams) and adjusted for correct free play before worrying as it may just be that?

or

B) An intermitent selector issue within the gearbox / outter selector mechanisms or the selectro shafgt bearings on the lay shft that the gear elver botls to that occasionally allows full set of gears with no issues and on others it wont select anything?

All further help glady appreciated as I cant see that ive done anything wrong when reasembling the levers etc

just seems strange that i have lost and regained gears in space of afternoon, selector mechanism wasnt touched when end cover removed only the clutch cable arm

[Super45]

Appolgies for spelling, fat fingers on small laptop keyboard

[Adrian]

Sorry if this is not much help with your gearbox, but if desk-top space permits, a cheap USB mouse and separate keyboard will ease your typing pain.

A.

[stinkwheel]

Lost 4th gear? Make sure the gear lever isn't hitting the footpeg. Don't ask how long I took to work this one out!



Should I imply you're not dynamically testing this. ie, the engine isn't running? I'd try it with the engine running before making any rash decisions about how the gearbox is working. You can run it for a reasonable time (long enough to test the gearbox is working in any case) without putting the primary cover back on.

[Super45]

Thanksd Adrian will look to invest

@Stinkwheel thanks will look at lever position and will try it running , just seems strange that ive lost 4th where as originally id lost 1st and 2nd, then it fixes itself after a fortnight in garage and the lever to my knowledge is on the same spline as it was before I took the cover off

[Super45]

Ok update, with bike running clutch drags bad enough that the bike stalls as soon as you engage first adjuster on clutch arm is stuck so cover needs to come off again to free it up, all levers free and don’t strike exhaust or the foot peg

Unable to locate 4th and other gears take a couple of attempts

However... when trying to cycle the gears by hand I pressed on kickstart( not running) and it found 4th all of sudden but then wouldn’t find neutral on way back down box seems selector gets stuck as lever won’t move further on correct direction as if it hits something yet feels free when it does drop into gear you selected

Any advice welcome

[vince]

Hi, check the mainshaft nut has come undone (lefthand thread) . Vince

[Super45]

Hi vince

How would I go about that? Is it easily accessible?
Thanks

[vince]

Hi, I assume we are talking about a 4 speed box. Remove outer cover. Remove the domed cover where the clutch pushrod protude from. Bear in mind the kickstart spring is attached to one of the bolts. Under this cover you will find the mainshaft secured by a lefthand threaded nut.if this nut is loose the mainshaft can float which affects gear selection. Also while there check the bearing which can also allow movement if worn. To clarify if the mainshaft can float, as you move the clutch pushrod the mainshaft and clutch will just move together and you will not get full clutch release. Vince

[Super45]

Thanks Vince will have a butchers and yes 4 speed

I did have to tighten the clutch basket nut as basket was moving around which i belive was part of the issue in the first place with the clutch vibrating itself loose so stands to reason other end might be the same also

If the bolt ends up being tight are there any other options?