Triumphrat

Caulky

My mate (ex Harley man) rode my bike today.
Initially he put it in second and stalled it.
Restarted, put in first gear and drove off out of sight.
I could hear it as he went around the block, about 1/4 mile or so.
"Everything is OK...it really pulls, but cant select any gear except 1st. Keep finding neutrals.
I was beginning to really enjoy the ride, try again Friday?
Maybe its the clutch."

I checked the clutch and re-adjusted it, cant fault it.
So, off comes the outer case and the inner case.
Now what?
Yes I know I should have taken the inner case off the last time.
I was convinced that removing the score marks on the plungers,
renewing the broken springs and the worn guide plate, would fix it.
Apparently not.
No obvious gear pinion wear.

68TR6R

Can you select the gears with the engine off? If so, it is probably the index plunger. When I installed my index plunger the holder was not true and the plunger caught when compressed. Of course I didn't notice it until after attempting to ride, and I could only get first. I pulled both covers to see that the plunger was not moving. Could have just removed the plunger and checked it first, but you know how it goes. If that's not the case, check your indexing.

bushybester

Gear boxes can be a real pain. I striped and reasembled mine about 20 times over a period of time as the bike was not road worthy at the time.

Two things come to mind Firstly the reassembly of the main shaft and lay shaft MUST be exactly correct. Secondly when indexing the gears I found the Hanes book not quite correct. I eventually drew a sketch of how the indexing took place and in what gear I was to fully understand it. I don't know if there are any great differences between the unit and pre unit gear boxes other than it is difficult to take them out competently. You need to get the bike onto a stand at eye level or just below. I did mine lying on the floor some years back and that’s not easy.

Remember that almost every thing is pivoted so when you move the gear lever up the other part is moving down and visa versa. This is where a hand drawn sketch will help understanding the workings.

You might have to strip to check that the gears are correctly assembled and check the indexing.

Good luck let us know how you get on.

Caulky

Sorry to go on, but I`ve no idea what to look for.
With the inner cover off, I can depress the camplate plunger with a screwdriver and oil squishes out.
It appears to be in 5th (top) gear.
The camplate has slight wear marks.
The camplate pinion has grooves on the teeth.
I can move the camplate sideways about 1/8th inch or so.
Also the selector fork rod.
The mainshaft and layshaft are still fitted.
Do I need to remove the gear clusters? and what for?
Cheers Dave.

Plewsy

Hi caulky,
Can you get all the gears by rotating the camplate?
do it a notch at a time, you will need to move the rear wheel and support the shaft ends.
The smallest notch on the camplate should be neutral.

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bushybester

Get the workshop manual and follow the instructions EXACTALY. You may have to remove the complete inners as these parts fit like a jigsaw puzzle. the important part is once you reassemble put it all back together fit the inner cover with two screws and then the outer cover and make very sure you have index it correctly. In other words do one or two dry runs before finally assembling it. Each time you assemble it select 1st and rotate the back wheel check the revolutions’ and the next gear and so on. The reason I say this is if you have not index the gears correctly you may be getting 2 or 3 gears only so you need to be 110% sure you know hats going on and getting the correct revoltion and that you are getting all the gears. This not a job to betaken lightly and it may take you several attempts to get right then again you might get right first time only to have to remove the covers to put in gaskets.


If the main and lay shafts with all the rears are correctly assembled and the plunger is in place when removing the inner cover be very gentle not move anything the slightest.

Indexing !!!!!!!!!!!!!!!!!!!

Caulky

The workshop manual (650 cc twins) says "Set the camplate in the neutral gear postion....When the cover is approximately 1/4 in. away...
position the camplate quadrant so that the top edge of the second tooth is aligned with the centre-line passing through the footchange spindle housing."
OK,
but Haynes says "check that the camplate is positioned so that the plunger engages with the depression BETWEEN second and third gear notches...otherwise the gears will not index correctly."
One of these is wrong! Or is Haynes talking about 4 speed boxes?
Does the T140 manual make it any clearer?

Now, at the start of this thread, I said it was in 5th (top) gear. (according the plunger and camplate).
Having reassembled the cases I found that it was indeed in gear.
But not top, 1st I think...moving the pedal upwards found (a) neutral.
Turning the rear wheel as best I could, further upwards movement found 2nd I think. And more movement had no effect.
In other words, I cant get 3rd, 4th or 5th by hand...no clutch.
Any recommendations?

Shel

The five speed can be timed in 1st or 5th.
With the cam plate in the first gear position let the quadrant drop under its own weight, offer the inner cover home until you meet resistance. Using your thumb press down on the quad about a 1/16 of an inch and push it home.
In the fifth gear position you hold the quadrant all the way down with your thumb as you offer the cover, as you meet resistance let the quad drop about a 1/16th of an inch and push the cover home.

RetroRod

Caulky,

You may already have a parts catalogue, but if not, it's very helpful in setting out the sequence of parts assembly.

That said, the sequencing can be a problem I know. I spent a day and a half sequencing for 5th gear when the thing was in 1st. Any wonder I could only get one gear!! When I finally got my head around it, it fell into place.

Have fun, it'll turn out OK in the end. RR

Webby

[QUOTE=Caulky;1420434]The workshop manual (650 cc twins) says "Set the camplate in the neutral gear postion....When the cover is approximately 1/4 in. away...
position the camplate quadrant so that the top edge of the second tooth is aligned with the centre-line passing through the footchange spindle housing."
OK,
but Haynes says "check that the camplate is positioned so that the plunger engages with the depression BETWEEN second and third gear notches...otherwise the gears will not index correctly."
One of these is wrong! Or is Haynes talking about 4 speed boxes?
Does the T140 manual make it any clearer?

Hi Caulky, The Haynes manual talks about the 4 speed box and LIES !In fact IMO the best thing to is throw the Haynes in the bin, It's useless! I found this out when I did a dry run assembling my box. The procedure you have mentioned from the manual sounds like it's for the 5 speed. It's in section DV (5 speed box) in my 72 manual.

Webby