[Bankerdanny]

OK, so I finally got a beautiful day here in Chicago, sunny and 60, so it was time to install the kick start pawl that I bought this winter.

I love the guys at CMW, but this is not a 1/2 job, at least not for someone without a lift or prior experience at this job.

Anyway, I got everything apart in about an hour and installed the new pawl. Then came the trouble, I just cannot get the inner transmission cover back on. It stops about an inch from the case and will go no further.

It looks like the problem is that the kickstart gear is too far forward (towards the outside of the transmission) and is not meshing with the high gear pinion on the mainshaft.  I can't find any reason for this and no amount of manipulating the box by rotating the wheel makes any difference.

I am at my wits end (and I really don't have many to spare). Has anybody done this job?

[Vince]

     Most likely one  of the gears fell off a transmission shaft. A parts book might give you a better idea on assembly. I use a parts book in conjunction with the service manual on many bikes. Study the drawings to see how the gears fit.

[Bankerdanny]

Trust me, I practically have the exploded drawing memorized. I think that I know what the problem is, but I don't think that I can fix it myself.

As I don't have a garage there are limits to how much I am willing to take apart and unfortunately I am pretty much there. I think I will have to take it to my local dealer.

On the plus side. I used the last part of a beautiful sunny Sunday to install new fenders and a new seat.

[Bankerdanny]

OK, Here's what my gears look like, as you can see the dogs are engaged but the main gear is too far forward and doesn't engage the main shaft gear above.



[old attachment deleted by admin]

[Vince]

     it looks like you have a 4 speed. If so the ratchet pinion does not appear to be on the lay shaft splines. Take it off and check for any burrs, then try to re install. You can call me at 1-866-VINCEMC. Good luck!

[Bankerdanny]

Thanks.

That pic doesn't resize well. Here is a scaled down one.

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[Bankerdanny]

I don't see how the ratchet pinion could move though. During disassembly there is no outward pressure on the gear other than some minor force as the pawl assembly is removed..

How would I pull the gear? I assume it is pressed pretty tightly in place. Can it be pulled without removing the whole gear box guts (sorry for the fancy technical language) or can I pull the ratchet gear by itself and leave the rest in place?

When the lay shaft is properly seated in its buching and the ratchet gear is also properly seated on the shaft, about how much space should there be between the 3rd gear dogs and the ratchet/main drive gear?

[Vince]

Do you perhaps have the pinion gears reversed? The one next to the ratchet pinion has 22 teeth. The next one in to the left has 19 teeth. Look very closely at the parts picture. The 22T gear has 4 radial slot in it. If that's not it I don't know what else to do without actually having it in front of me. Let me know how it turns out.

[Bankerdanny]

Vince,

I am able to pull the lay shaft partially out. I have assumed my problem is that when i push it back in it is not properly seating in the bushing at the back of the box.

This is what it looks like with the shaft pulled out.

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[Vince]

  You may be right. You may have to remove the clutch, take out the transmission, then re install.

[Bankerdanny]

Unfortunately, without a garage that is a bit more than I am willing to do. It lloks like one of my local dealers will be getting a service call from me.

[deejay]

30 minute job my @ss, CMW needs to update the description of the pawl

[Bankerdanny]

No argument from me obviously.

Even in a best case scenario it would be an hour to take apart, replace, reassemble, refill the box and adjust the shifter.

[Mr_Gently]

I have a screwed up kick start as well, but I haven't started on mine yet.  The weather has been nice lately, and I've either been working on other projects or riding my scooter.   When you get this all back together, I hope you'll tell us all what the fly in the ointment was.   I'd like to avoid having my bike apart for too long!   I don't have a dealer handy, so I'm going to have to do it myself.

[Bankerdanny]

I certainly will.