More problems?

[johnr]

if you put the bikes wheels on a but of inch ply, and then put the sidestand down, but not on the ply, so it leans further over, you can take the clutch cover off without losing any oil.

[Uncle Bob]

I was going to mention about the gear shaft binding on the sprocket cover as I had that on the 400, but you beat me to it.
Sounds like you have a plan now though, so just waiting for the weather to turn (which this way it is refusing to do which is nice - in the low 20's again today).

[PaulD]

if you put the bikes wheels on a but of inch ply, and then put the sidestand down, but not on thee ply, so it leans further over, you can take the clutch cover off without losing any oil.

Now that sounds like a plan
As I said I was going to leave it but I've got this morbid fear of the quadrant spring breaking in half and a bit of it getting jammed in the clutch or somewhere

[johnr]

if the spring is duff, ive got one you can have. its also possible that the shaft has been bent if youve hit something with it perhaps whilst moving it around.

[PaulD]

if the spring is duff, ive got one you can have. its also possible that the shaft has been bent if youve hit something with it perhaps whilst moving it around.

Thanks John your a star, I don't think the shaft is bent because it fits through the sprocket cover nice & easy and as I said earlier it just seemed to happen all of a sudden. If I get chance ill whip the clutch cover off tomorrow and have a look at what's going on. Hopefully it's summat simple like the return spring. Fingers crossed

[PaulD]

Right I’ve stripped the clutch cover off this morning but the spring is fine? I had intended to pull the gear change shaft out but that involves stripping the clutch out so I’ve left well alone. While everything was stripped the gearchange while not 100% perfect was a lot better? I reassembled everything and the problem returned I did notice before tightening the sprocket cover up it was passable but when I nipped it up it seemed to play up again. I’ve found that if I tighten it up from back to front the change seemed better? I might open the hole in the sprocket cover up a tad and see if that improves matters, what do you think?

[fossie]

I would look at the fact it was ok before the Chain was removed, so what ever happened, happened then.
Personally I would sand off the pivot and hole where the gear-lever attaches and lightly oil it.
This lever is held on with a washer and circlip, try without washer see if that makes a difference.

It isn't unusual for this shaft and the rear brake shaft to collect gunge which acts as a friction agent slowing the spring action down.

[PaulD]

[quote="fossie"]I would look at the fact it was ok before the Chain was removed, so what ever happened, happened then.

Ok I see what your saying but this problem happened weeks and many miles after I had the chain problem?

Personally I would sand off the pivot and hole where the gear-lever attaches and lightly oil it.

When you say pivot hole so you mean the bush cast into the sprocket cover? If so This is what I was considering reaming out slightly with an adjustable reamer.

This lever is held on with a washer and circlip, try without washer see if that makes a difference.

If I remove this washer/shim there is a chance the gear quadrant will rub the back of the clutch basket (i checked )

It isn't unusual for this shaft and the rear brake shaft to collect gunge which acts as a friction agent slowing the spring action down.

GUNGE? How very dare you have you ever seen my bike? The area behind the sprocket cover is as clean as the day it came out of the factory! My bike is shiny even on the parts you don't normally see
[quote/]

[fossie]

I mean the actual gear lever, by the foot peg, over time the actual lever becomes oval and the lever gets side movement which is taken up by a washer, this is the area that gets ingress........posh gunge!

[PaulD]

I mean the actual gear lever, by the foot peg, over time the actual lever becomes oval and the lever gets side movement which is taken up by a washer, this is the area that gets ingress........posh gunge!

Right gotcha
No mate that bits ok, I’ve got a feeling that either the sprocket cover is warped somehow or as johnr mentioned the actual gearchange shaft is bent. The problem is unless I strip the clutch basket I can’t pull the shaft out? I’ll leave it for now and have a look again over the winter when I sort the top end out.