gearbox problem help please.

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BigLT
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gearbox problem help please.

Post by BigLT » Sat Aug 21, 2021 8:53 pm

After finally getting my katana on the road it was riding, handling and running beautifully, until I couldn't change gear. I was within a mile of my house so nursed it home in first.

The clutch disengages with the lever as usual, so I can wheel it around, but I can't change it out of gear.

I'm hoping that someone will point out something really stupid that I might have done, or that I should check. I had the engine out during the build, but didn't go into the gearbox.

Any suggestions would be very gratefully received....I'm not sure I can face stripping it all down.

thanks in advance.

Liam

ps gsx750sz engine with about 10000miles. Wiseco 816 kit. standard carbs jetted. Anything else you need to know?
pps - this is under resin corse kat in projects. I was about to start prepping the bodywork on the day the gearbox 'went'.

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Re: gearbox problem help please.

Post by fossie » Sat Aug 21, 2021 11:07 pm

To be honest I'd start with the gear lever, if it's too close to the foot peg when in the selecting position it feels like the gearbox has issues . Another easy possible is chain adjustment.
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Re: gearbox problem help please.

Post by BigLT » Sat Aug 21, 2021 11:38 pm

Thanks Fossie, I have looked there, but I'll look again tomorrow and try different positions. I don't know why it would be working before and not now though. Maybe something's come loose or moved.

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Re: gearbox problem help please.

Post by Pedda » Sun Aug 22, 2021 12:57 pm

Have a look at the circlip part no. 32. If you lost it or it just found its way out of the notch, the gear change shaft might have moved a few mm to the rhs, pushing that little actuator gear at the right end out of action. Just a bit playin around with the gear shaft pulling it back home and securing the circlip again might do the trick.
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Re: gearbox problem help please.

Post by Pedda » Sun Aug 22, 2021 5:45 pm

Errm... when I say rhs I mean riding direction wise obviously, not plain looking at the pic. But I bet you knew anyhow...

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Re: gearbox problem help please.

Post by BigLT » Sun Aug 22, 2021 7:41 pm

Thanks Pedda. I'm going to be in the garage trying everything and praying tomorrow.

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Re: gearbox problem help please.

Post by BigLT » Wed Aug 25, 2021 8:58 pm

Right, errr, embarrassing admission:

Went through everything and finally noticed that the gear selector rod had 'unscrewed' itself so that the joint butted up against the bottom of the footrest when I tried to change down. I obviously hadn't tightened it properly when I was setting it.

Tightened it up, adjusted the clutch cable and it now changes fine. I rode it to Loomies and back tonight.

Thanks again for all the advice and apologies for taking up your time. At least I know I have double checked everything now.

yours embarrassed...

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Re: gearbox problem help please.

Post by Smallkat » Wed Aug 25, 2021 9:33 pm

At least it was an easy fix!
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Re: gearbox problem help please.

Post by fossie » Thu Aug 26, 2021 7:30 am

You won't be the only one ...how do you think we pointed you to it ;) .
There's no embarrassment in asking, that comes if you don't! :lol:
Last edited by fossie on Thu Aug 26, 2021 8:22 pm, edited 1 time in total.
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Re: gearbox problem help please.

Post by Pedda » Thu Aug 26, 2021 3:23 pm

Better you being embarrassed than us, haha.

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