Splitting the cases re transmission work.

[Guest]

As I mentioned yesterday, the inaugural run of the Kat project was severly hampered by the inability to shift out of first. I haven't had the opportunity to get the bike back on the lift to explore what's going on but I did do my review of the manuals and it seems I may have to 'dive in" to the tranny. I hate the thought.

What I wonder about is if I can get to the tranny without dissassembling the whole engine as per the manuals? I did a search and there is a post from 2007 indicating that it was possible but the engine in question was a 650 I believe.

Are the engine blocks and cases all similar? Can this be done with the larger blocks and if so does anyone have any tips?

I have a spare engine and while I could cannabalize it for parts I don't know its history and it does look quite well used so I doubt it would be a candidate for transplant.

I appreciate any input.

Cheers all,
Spyug

[Nessism]

Well that sucks. Sorry to hear about this complication.

To service the transmission you have to split the cases. My understanding, although I’ve never done it, is that you can turn the engine up side down with the cylinder/head still attached, and then remove the bottom crankcase half to gain access to the trans. Before attempting something like this I suggest you scheme some way to hold the engine securely. If you have a spare engine maybe you can practice on that one?

[tkent02]

Are all of the shifter parts that you can see without splitting the cases OK?
Does the shift lever move?

[spyug]

Thanks guys.

About 2 months back when I was putting on the shift linkage, I was sure there was a problem with the tranny as I couldn't seem to shift it at all. After moaning here about that a few of the guys pointed out that the tranny needs to be turning to engage gears so it was suggested to turn the back wheel while attemting to shift. That did seem to work.

Yesterday when riding ( if that's what you call it) I could pull away smoothly in first but could not get it out of gear and into the next. When I stopped and got off ( engine off) I could hand shift with a bit of a struggle out of first and into second and third then back down again. The shift linkage is sloppy but it does function.

From my reading of the manuals and thinking about it I suspect there is an issue with the gear selector mechanism and likely the selector forks and the only way I can know for sure is to dive into the tranny. I was looking for the easiest method.

At this point, I am going to get the bike back on the lift and will pull the side cover and selector switch to have a look at the end of the selector drum as I try to turn it with the shifter. I'm not sure if that will tell me anything but its a start plus I do have an issue with the neutral light being on all the time.

I was thinking of using the spare engine for a tester and will likely rip into it in the next day or so.

Man this bites.

I'll let you know how it turns out.

Cheers guys,
Spyug

[rapidray]

PM replied to Andy. Ray.