[bobbb]

hi all, my 300 sat for like a year with the left cover off. I started to replace the stator and things happened and I was side tracked. Now I have a new stator in and bike is running again but won't shift. I did screw up and let the shift spindle come out with the side cover. Everything I've read says to remove the right side cover to ensure the shift spindle lines up correctly.

My question is with the bike sitting for so long with no oil, will that cause a problem shifting? would/should I still be able to shift by hand after sitting so long? or is my shaft just not lined up?

tks

 

[fishfiles]

maybe the clutch plates on the shift clutch are stuck together

 

[bobbb]

Thanks for the reply... I found out if I pull the shift arm/spindle out I can shift through all the gears by turning the shift drum manually with some pliers. When I put the shift arm/spindle back in, it will downshift but it will not upshift.
For instances if I manually turn the shift drum to 1st, 2nd, 3rd or 4th gear with the shift arm out then put the shift arm back in, it will downshift back to neutral no problem but it will not shift back up to first gear or any gear. It will also down shift into reverse but will not shift back up to neutral. will not shift up at all.

I saw in another post that the shift arm has a punch mark on the end of it that's suppose to line up with an arrow on the case on the right side. This is probably going to be my problem. I should not have pulled the shift arm out..

Does anyone know if it's possible to get it back in correctly without having to remove the right side engine cover, or is removing the right side cover the only way to get it lined back up? I would think Iif i kept trying I'd have to hit it right eventually. but maybe not. This is all new to me.

tks again

 

[fishfiles]

the mark on the case needs to line up with the shaft , but it is not a perfect match , if you go up then it is a little off , down and still a little off --- I have had that happen to me

 

[bobbb]

Okay I took the right side cover off, to get this thing lined up... but I still cannot figure it out. On the shift shaft, the only mark I see is on the very end, a tiny punch mark (dot). Is this dot suppose to line up the the arrow on the case? or am I missing something. In order for me to get this mark lined up with the arrow the shift shaft has to be almost turned almost vertical, in this position it's nowhere close to lining up with the guide plate assembly on the drum on the left side. Also the change clutch arm has a punch mark on it. Is the punch mark on the shift shaft suppose to line up with the punch mark on the change clutch arm? The manual only says not to let the shift shaft come out, it doesn't say anything about what to do if it does come out.

tks for the help

 

[bobbb]

Okay, I think I got it figured out. There's no mark on the actual shift shaft/rod or spindle as the manual calls it. The shift spindle when inserted on the left side ONLY goes in one way, and that's where it lines up with the Guide plate assembly on the shift drum. There is a mark (tiny dot) on the end of the shift spindle but this means nothing as far as I can tell, it doesn't line up with anything.

The alignment happens on the right side. when the shift shaft is stuck through and is aligned on the guide plate assembly (on the left side)then you stick the CLUTCH LEVER onto the shift shaft where's it's sticking out on the right side. There's a punch mark on the clutch lever that aligns with the arrow on the case. The clutch lever also sticks into the v notch on the Clutch lifter cam. For some reason I was thinking the dot to line up was actually on the shift shaft/spindle, it's not it's on the clutch lever.

What happens when the shift spindle is pulled out is the clutch lever falls , in my case it fall back, preventing any upshift. If it fell forwards there would be no downshift.. BUT, when the shift spindle comes out (on the left side), the right side cover must be removed to align the clutch lever with the arrow on the case. When this is aligned, the clutch lifter cam sits down on the clutch lever. So I'll get some photos up as soon as my camera charges. Just need to get a couple new gaskets now.

Anyone know if gasket RTV stuff should be used or not?

 

[retro]

Hey, you nailed it bobbb! I couldn't have explained it to anyone as well as you have... congrats!

Do not EVER use RTV sealant on these motors during assembly. Use Hondabond 4 or Yamabond 4 (same stuff) on rigid cases and use gaskets everywhere else they were intended to be. RTV sealants cause clogging problems with the oiling systems... avoid them wherever possible.

 

[fishfiles]

when you think you got it right , just put two bolts in the right cover , try to shift it by hand with the engine not running , before you put everything back on and then find out later that it only shifts either up or down ----if you are one spline off , then it will shift up but not down , the other way is vice-versa