gear selection issue - can't get 3 & 4 (I think)

I am on the final stage of getting my bike ride-able, and I've hit a snag.

Part 1:

Took the transmission apart to do the layshaft bearing swap (and yes I had the dreaded OE bearing).

Transmission checked out well. Had the bike in all 4 gears plus neutral while on center stand. Also took it for about 25 feet walk with it in high gear, spark plugs out, just to see if breather was working, etc.

During the walk realized clutch would not disengage even though cable was working diaphragm moved, etc. Primary off, found two clutch friction plates had frozen to neighboring steel plates.

Part 2:

Bought new Barnett friction plates - the 5 plate type, checked out at 0.125" thickness each (with minor variation).

Replaced clutch, put primary cover back on, can't seem to find anything other than 1st, neutral, and I presume 2nd (shifts into something, don't know how to verify it's 2nd).

Haven't tried doing anything more than rocking the rear wheel on the center stand - didn't want to screw up something. Nothing else changed on bike between all gears working with frozen clutch to new clutch, can't find all gears.

Ideas?

Try walking the bike again and shift through all the gears.

Unless i'm misunderstanding you, you are trying to find 3rd and 4th with the bike on the center stand?

I have never been able to get 3rd or 4th on the stand. Need to have the bike in motion and or rotate the rear wheel a full rotation before it will engage 3rd or 4th.

yesterday we wanted to check the valve clearances

so, bike on center stand

plugs out

crouched on right side of bike, left hand on rear wheel gently tapping it forward rotation couple inches at a time

easily moving gearbox from nuetral to second to third to fourth

no clutch lever usage at all

I have never had any difficulty going through the gears this way, no need to walk the bike to shift it

lbridges said:

Haven't tried doing anything more than rocking the rear wheel on the center stand - didn't want to screw up something.

Click to expand...

If you are only rocking the wheel through the "backlash" range of the gearbox then that may not be producing enough internal shaft rotation to be able to select all gears straight through from 1st to 4th.

L.A.B. said:

lbridges said:

Haven't tried doing anything more than rocking the rear wheel on the center stand - didn't want to screw up something.

Click to expand...

If you are only rocking the wheel through the "backlash" range of the gearbox then that may not be producing enough internal shaft rotation to be able to select all gears straight through from 1st to 4th.

Click to expand...

I was - thanks, will try again.

Thought I would update, just in case someone confronts the same problem. I think Les hit the nail on the head.

Took bike for a one block shake-down run, and all 4 gears work.

lbridges said:

Thought I would update, just in case someone confronts the same problem. I think Les hit the nail on the head.

Took bike for a one block shake-down run, and all 4 gears work.

Click to expand...

Yes, when the gearbox is static, with no shafts rotating, then it's a matter of chance as to how many of the gear dog pairs will have stopped in exactly the right position for engagement. It could be one, two, three or all four.