gearbox problem help please.

[BigLT]

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'.

[fossie]

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.

[BigLT]

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.

[Pedda]

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.

Screenshot_20210822-144511.jpg (35.15 KiB) Viewed 1059 times

[Pedda]

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

[BigLT]

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

[BigLT]

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...

[Smallkat]

At least it was an easy fix!

[fossie]

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!

[Pedda]

Better you being embarrassed than us, haha.