shifter fork installation, 1990 FXRS
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Cruiser
Joined: Sep 2011
Posts: 101
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From: Truckee
shifter fork installation, 1990 FXRS
I can't get the #3 shifter fork (for 3rd and 5th gears) to sit into it's slot on the mainshaft. I know I'm installing the shifter forks in the right order, as I took a photo before removing them.
For kicks, I tried to install the #1 shifter fork where the #3 should go. It slid into place just fine. #1 and #2 shifter forks slide into their proper spots onto the mainshaft and countershaft
The #3 shifter fors does not appear to be bent and the tips are well within tolerances.
What the heck am I overlooking? Been at for over an hour and I'm about ready to grab a hammer.
For kicks, I tried to install the #1 shifter fork where the #3 should go. It slid into place just fine. #1 and #2 shifter forks slide into their proper spots onto the mainshaft and countershaft
The #3 shifter fors does not appear to be bent and the tips are well within tolerances.
What the heck am I overlooking? Been at for over an hour and I'm about ready to grab a hammer.
Thread Starter
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Cruiser
Joined: Sep 2011
Posts: 101
Likes: 9
From: Truckee
Spanner, let me add some more details. Here's what occurred to get me at the point today:
1) removed shifter cam
2) removed shifter forks and rod.
3) removed trap door with mainshaft and countershaft
4) removed main gear and main bearing.
5) installed new main bearing
6) pressed new needle bearings into main gear
7) pressed main bearing into main bearing
8) inspected and installed trap door with mainshaft and countershaft
Everything fell into place. All shafts and gears spin freely. It's the #3 shifter fork that won't fit into it's proper slot, but it easily falls into the other two slots. The #2 and #1 shifter forks will both fit into the slot where the #3 fork is supposed to be.
Thinking about sliding trap door out, placing the #3 fork into it's proper slot and then sliding the trap door back into place. But I'm wondering if I'm just hiding a problem. Could I have made an error in steps 1 thru 8 above that is causing this? I really appreciate your help. Thanks for the quick response.
1) removed shifter cam
2) removed shifter forks and rod.
3) removed trap door with mainshaft and countershaft
4) removed main gear and main bearing.
5) installed new main bearing
6) pressed new needle bearings into main gear
7) pressed main bearing into main bearing
8) inspected and installed trap door with mainshaft and countershaft
Everything fell into place. All shafts and gears spin freely. It's the #3 shifter fork that won't fit into it's proper slot, but it easily falls into the other two slots. The #2 and #1 shifter forks will both fit into the slot where the #3 fork is supposed to be.
Thinking about sliding trap door out, placing the #3 fork into it's proper slot and then sliding the trap door back into place. But I'm wondering if I'm just hiding a problem. Could I have made an error in steps 1 thru 8 above that is causing this? I really appreciate your help. Thanks for the quick response.
Seasoned HDF Member
Joined: Dec 2010
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From: Coromandel Peninsula New Zealand
Hmmm, was it in the right place to start with?
Here's what I would do.
With the selector drum to hand I would put the forks in whatever order they work and still sit in the selector drum grooves.
Then I would (with the top off the gear box) make sure it changes gears OK.
If it does then fine, leave it like that but if not, if that fork has to go in that slot I would get in there with a powerful torch and see what the go is.....the only things that will stop it going in are misalignment (bent or wrong fork) and damage to the fork that makes the end too fat.
Best I can do right now.
Here's what I would do.
With the selector drum to hand I would put the forks in whatever order they work and still sit in the selector drum grooves.
Then I would (with the top off the gear box) make sure it changes gears OK.
If it does then fine, leave it like that but if not, if that fork has to go in that slot I would get in there with a powerful torch and see what the go is.....the only things that will stop it going in are misalignment (bent or wrong fork) and damage to the fork that makes the end too fat.
Best I can do right now.
Thread Starter
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Cruiser
Joined: Sep 2011
Posts: 101
Likes: 9
From: Truckee
Good suggestion that led me to the problem.
Removed trap door and main/counter shafts. Installed shifter forks and drum on bench. Things became very clear.
The second gear on the mainshaft was installed backwards. This didn't allow the #3 shifter fork to fall into it's slot, nor slide to the right far enough to fit into the drum. Slid the second gear off, spun it around and everything fell into place.
Please don't make fun of me behind my back - I deserve it publicly. :-)
Thanks again for pointing me in right direction.
Removed trap door and main/counter shafts. Installed shifter forks and drum on bench. Things became very clear.
The second gear on the mainshaft was installed backwards. This didn't allow the #3 shifter fork to fall into it's slot, nor slide to the right far enough to fit into the drum. Slid the second gear off, spun it around and everything fell into place.
Please don't make fun of me behind my back - I deserve it publicly. :-)
Thanks again for pointing me in right direction.
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