Gear - fork misallignment

Well, this one is a real head scratcher, shift fork will not engage drum
Gear moves smoothly, shift forks look straight, looking for ideas, anything is possible.

There's no reason why that should not go in.
The gear needs sliding to the right a little and the fork needs lifting a touch for the pin to locate in the drum track and the shaft to slide through the fork pivot.

First, the detente should be in neutral. Yours looks to be in some other position.

Second, it looks like the left shift fork in your photo is not correct. Here is a similar photo of my last rebuild.

Edited to add...are you trying to put the shift forks in place AFTER the cases are together?

Here is a photo of the detente from the side.

hardrockminer wrote: First, the detente should be in neutral. Yours looks to be in some other position.

Second, it looks like the left shift fork in your photo is not correct. Here is a similar photo of my last rebuild.

Edited to add...are you trying to put the shift forks in place AFTER the cases are together?

Everything is correct in his pic except the gear being over to the left and the fork pin is not in the track so it is currently not in the neutral position like yours .
However it does looks different to yours because even though your 3rd gear fork is laterally correct in relation to the cluster it is not correctly located on it's gear so is in an incorrect rotational position as is the drum
The two forks on the common shaft can be removed and refitted without splitting the cases.
The fork that is not located though does look slightly narrower on the shaft in the first pic which may be the pic angle as they appear to be identical in the second pic which they should be although that alone should not prevent the fork from going in.

Try swapping the forks and see if the problem moves with it.

Eff....you're right zed1015. I went back and checked my photos. That one was taken with the cases together but not sealed. I must have corrected it when I put the sealant on the cases. This one was taken after sealing.

The drum in 73Z1's photo looks to be incorrect. The shifting grooves are different than my last photo. I wonder if that's what's wrong?

hardrockminer wrote:
The drum in 73Z1's photo looks to be incorrect. The shifting grooves are different than my last photo. I wonder if that's what's wrong?

Bloody hell the light bulb has just come on . I must be getting slow :laugh:
That gear is fourth gear with the neutral bearings in.
The gearbox isn't in first or neutral and the fork won't move over because of the second gear lockout bearings preventing the gear sliding any further across.
The drum needs rotating to neutral or first and the fork will drop in the slot..

>>> "Bloody hell the light bulb has just come on . I must be getting slow :laugh:"
I feel the same.


>>> "That gear is fourth gear with the neutral bearings in.
The gearbox isn't in first or neutral and the fork won't move over because of the second gear lockout bearings preventing the gear sliding any further across.
The drum needs rotating to neutral or first and the fork will drop in the slot.. "

Thanks for everyone that came to my aid, there are three little bearings in 1st gear that lock out 2nd gear until the bike moves.