Yes so, took it for a spin and the clutch was Very Hard to pull so had the clutch adjust cover off and went up Till 3 gear i think, it had a Hard time shifting.
Then the screw came off the clutch adjuster and No more shifting. Ive fixed the adjuster but the damn bike wont get into neutral or Any other gear Its stuck in 1? I think
What can i do and Any suggestions to what happended?
Total restored bike
Will it shift with the bike shut off and rocking back and forth?
Nope.
Cant get it out of gear 🤷♂️
Stuck shift and hard clutch? Clutch push rod may be bent. If that holds the clutch open your bike won't rock and shift. That or something internally is broke. Bits and bobs get lodged and cause trouble.
"Total restored bike"
Does that mean you had the engine split and apart and you reassembled? If so there could be multiple things wrong. But sounds to me that a shift fork or two are not in the proper place. It I think you'll need to split the engine and investigate before you ruin something.
Yes engine is a total rebuild.
But I had it running and shifting somewhat good but after adjustinf and playing with the clutch cable things started to go south.
As if the clutch wont engage proper, maybe investigate on the clutch side before i start thinking of the i possible.. Removing the engine :smiley:
Quote from: rd400greenhorn on May 30, 2021, 02:56:40 PM
Yes engine is a total rebuild.
But I had it running and shifting somewhat good but after adjustinf and playing with the clutch cable things started to go south.
As if the clutch wont engage proper, maybe investigate on the clutch side before i start thinking of the i possible.. Removing the engine :smiley:
Yes, and check out the shift shaft and the bracket that rotates the shift drum for problems.
Forgot to tell
The clutch actuator was busted where it meets the push rod, not sure how but something wrong. It was brand new
Even if the clutch is not disengaging properly it will still shift properly. It will just be difficult to find neutral unless the engine is turned off.
Oh man...would hate Taking the engine out and apart. Its literlly done 10km, 6 miles. :guinness:
For starters do as 1976RD400C says.
Allright. Have removed the engine cover and first the circlip that holds the plastic wheel was off..
Removing the clutch Nothing looks out of the normal i think.
I believe the shift shaft in this engine was from a xs 400, early model, should be fine?
Not sure how i can test from here, maybe relocate the clutch and try shifting
So.. Removed the shifter fork and it was Very loose in the spring
Had a spare and put it together but not much improvement.just pushibg the bike back and forth.
I fear its the shifter drum Which a total engine tear down.., 🙄🙄
Seriously.. Iam not in the mood for Taking everything apart and engine cases to change the gear drum, but it seems like thats to fault. It wont shift, unless i give it a little help on the drum when the cover is off
Do you have a magnetic drain plug. They can be too long and make contact with parts inside.
So, no original drain plug.
Took the engine apart. Wierd - there was this piece of Bent metal sitting behind the oil cover?
Besides that everything looked fine No metal shawings or Any thing.
I removed the shift drum and compared it to Extra spare parts rd400.
Is it the right drum? They are pretty different...
The one i removed from the rebuild engine is the one on the left!
cant tell the size of the mangled washer, but it could be from behind the circlip that holds the tach drive gear on (plastic gear you mentioned came off)
FYI You can assemble the trans and finger tighten the clutch to hold everything in place in just the lower case and shift away and check everything before installing the top case piece on.
Thats a good tip, Thanks :)
Ahhh yes i believe your right. There is a washer behind the circlip. Awsome will find replacement tomorrow
I actually suspect that maybe the shift drum i put in the engine is a Rd350 ac model? When dinding pictures on ebay they look similar with the size of holes
Pretty sure there was an old thread that mentioned the 350 drum will work with 400 trans
Quote from: rodneya on May 31, 2021, 02:35:27 PM
Pretty sure there was an old thread that mentioned the 350 drum will work with 400 trans
Yes it works.
Ah okay. Damn... Hmm.. Not sure what i can be then but Will try tomorrow with a different drum and dry run some shifting before doing anything Else
Just remember that you will have to turn the sprocket a little by hand while shifting when you test or it will not shift.
Allright. Been at it all day not sure what to think. I have put transmission in and shifted through the gears, but how easy should it be, being and old bike? I am shifting just lower engine case with Nothing but gears in the casing.
Okay, gears are not working as they should
No were near shifting consistent just crap.
I have narrowed it down to believe Its the forks and or the axles they run on and the pins that run on the drum grooves.
Seems like those pins would benefit from having springs behind Them so they follow the grove 100 procent, Its as if they have a tendency to get stuck... No real damage to the drum either..
What do your forks look like? Is there wear on the outsides of the points?
Only pictures i got now. I have several forks but these for one
Does the shift drum rotate for every shift and detent itself without the shift forks engaged to it?
So, it was shifting fine and then suddenly stopped? The only damaged part I see was the rather mangled part you pulled out from behind the clutch cover. That shouldn't be there, hence its the most logical.
Either A: That part was the cause for concern and all is well (from the pictures the part wear looks fine). or B: The forks and pins are assembled on the drum grooves incorrectly. It is entirely possible to do so. I checked mine on re-assembly and had a stuck shifter. I had a fork on the wrong groove in the drum.
If the drum rotates free and you verify the shift fork positions then my money is on that mangled piece of metal binding your shift mechanism up.
Well not sure if it shifted fine, it shifted but needed force.
The manglede piece i believe is a shim from the tacho drive gear, but your right,gonna check that. But iam almost 110 procent sure the forks are in correctly but I will check again Thanks
Yeah so if i only have the drum in and turn that it turns fine and sits everyt time in the plunger? That goes from undernearh the engine case up in the drum
Now post a pic of it all assembled in the lower case. :pop:
Lower casing
Here
Hmm another observation
Did a dry shifting without gears and even though i held the forks up, they seem to get stuck on the drum preventing the drum to spin freely into each gear...
Not good
Oh well moved on and put gears in, tried a different drum and it shifts but not consistent.
Espcially 1 and 2 gear can be tricky at times...
And would a chemical cleaning of the gears do Them good? Just thought maybe it would shift easier, move Between the gears easier?
I need a new gearbox 😂
Do you have any oil on there? Needs to be oiled a bit.
Try with the gears in, a little oil and rocking the sprocket back and forward wile trying to shift.
I have done just that and it shifts but not as consistent as I would want it to. And sometimes 1 and 2 gear can be difficult.
Other times it shifts pretty solid.
Not good enough for assemble, it needs to be right.
Who put it together last time ????? And where did that washer pass through ? You usually don't crunch one piece of steel without it affecting another !
I did!.
Everything looks fine but the lock washer that was used was to big, so it did not hold for long.
That problem is solved now with new shim and correct lock washer.
I Will try to add clutch or pipe to tighten the clutch drive in so when shifting it Will be more like normal condition. Fingers crossed it Will be even better
So got the bike back up running, it appears to shift nicely. Only did until 3 gear, no gear on so gotta take it slow
Will do proper test tomorrow i Hope. When i got back it leasked heacily out of the seal where the push rod for clutch goes..
I Hope this can be changed without Taking cases apart. It does not sit in Any reces that i know
Yes you can change it without splitting the cases.