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Xj600 84 gearbox installation wrong

Discussion in 'XJ Technical Chat' started by mark1911, Mar 14, 2020.

  1. mark1911

    mark1911 Member

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    IMG_20200314_181356.jpg 15842104639763351272259336105114.jpg IMG_20200314_181513.jpg IMG_20200314_181356.jpg Got my engine back together recently and realised that I couldn't engage neutral and place the bike in gear. Followed the Haynes manual but am getting stuck somewhere how do I get the shift forks to engage into the drum properly do they have to be placed in a certain sequence in the groves etc. Have them numbered correctly I think with them facing the right side of the case, supplied some pictures above.
     
  2. Franz

    Franz Well-Known Member

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    The pins on the selector forks need to engage with the tracks in the drum. Looks to me like forks 1 and 3 are the wrong way round.
     
  3. cds1984

    cds1984 Active Member

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    Not sure if this pic helps but...
    A view from the sump...
     

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  4. Franz

    Franz Well-Known Member

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    Should fork number 1 be where fork number three is and vise versa? I would remove the shaft they slide on and change their positions so that taking the picture from the same angle the forks read 3, 2, 1 instead of 1, 2, 3 to see if that fixes the problem.
     
    Last edited: Mar 15, 2020
  5. Franz

    Franz Well-Known Member

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    No the Haynes manual states the selector forks have to be installed 1, 2 3 from the gearchange side of the engine so forget about reversing the forks.
     
  6. cds1984

    cds1984 Active Member

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    I do know from splitting and re-assembling you need to take care in aligning the forks into the gears.
    Not hard to let the forks flop all over the place.
    I did have to re-align everything the first time I did it as after moving the shift drum I could see that the forks weren't where they were supposed to be.
     
  7. Franz

    Franz Well-Known Member

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    Yes it is so long since I did this last time was on my Honda CB 750 years ago.
     
  8. mark1911

    mark1911 Member

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    I think am getting stuck on the travel section of the drum. It could possibly be its at the end of its travel not the beginning possibly. But how do you know if ur at the beginning or end of travel, had it confirmed that I have the dogs and forks right way around.
     
  9. Franz

    Franz Well-Known Member

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    Do you have a locating pin for the selector drum and it is installed properly?
     
  10. Franz

    Franz Well-Known Member

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    Yamaha XJ 600 F Gearbox.gif
     
  11. mark1911

    mark1911 Member

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    IMG_20200321_160517.jpg IMG_20200321_160450.jpg IMG_20200321_160702.jpg
    Hi mate yeah I have the selector pin correct and have the change lever spring positioned on either side of the guide bar as it states in the manual. Unless I have the change lever installed incorrectly or the wheel at the back of the drum is installed incorrectly but looks OK to me.
     
  12. Franz

    Franz Well-Known Member

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    Yes it looks ok to me too.
     

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