The gear linkage fell off the pinion on the back of the gearbox on my Metal Stone yesterday. Simple enough to put back on. But is there a trick to tightening the bolt on the clamp that attaches to the pinion? I spent two hours with fingers jammed into the frame with a L-shaped allen key trying to tighten it. I'm not happy about how tight I've manged to get it. The bolt head is on top of the clamp - if it was beneath the clamp I could get my 6 T-bar hex onto it and tighten it in a jiffy. If I remove the battery
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Re: Gear linkage problem
Does the battery tray remove easily to allow acces to the pinion?What if you replace the allen cap screw with a hex cap. Mine is a hex and it's fairly easy to remove and install with a 10mm wrench. Of course I'm talking about a different model here? Just a thought.,
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From Spyder's tech Tips, section entited: Wrenching Tips for Starter Pinion Gear
The starter pinion gear attaches to a splined endshaft on the starter gearbox assembly. The pinion gear is the gear that spins the ring gear attached to the clutch basket. Unless this gear is installed correctly the assembly can come apart and leave you with a pile of aluminum filings and a milled out extension shaft end support!
When installing the pinion gear on the splined endshaft you will install a splined washer, a spring, a flat washer, the pinion gear, a lockwasher, the extension shaft and the bolt that holds the whole thing together - in that order. The extension shaft is locked to the pinion gear by a lockwasher that fits between the gear and the extension shaft itself. IT IS EXTREMELY IMPORTANT THAT THE BOLT IS TIGHTENED ENOUGH TO COMPRESS THE LOCKWASHER FULLY! If the bolt is not tight, the bolt will work loose and eventually cause the pinion gear to become detached from the endshaft spline.
It may be necessary to RED Locktite the screw that holds the endshaft to the starter jackshaft spline. You can use a propane torch (CAREFULLY!) to heat the bolt and break the Locktite bond if you wish to remove the bolt at a later date. Of course, WHENEVER YOU USE AN OPEN FLAME ANYWHERE NEAR YOUR BIKE YOU SHOULD DRAIN THE GAS TANK(S) into a legal and safe container.
The problem is that the endshaft turns in a clockwise direction as the starter is activated. Although the endshaft is held in a bushing, the resistance to turning will cause the endshaft to apply a force in the counterclockwise direction, tending to unscrew the bolt that holds the endshaft in place and compresses the lockwasher. It would be ideal if the endshaft bolt was left-hand threaded, but then it wouldn't mate with a stock starter gearbox endshaft spline.
It is a false neutral, common on older Harleys. Change tranny oil to the correct grade, check old stuff for metal. Adjust clutch and tighten shifter linkages, take out all the slop and it should shift better. If not then a look inside the gearbox would be called for.
HI IF THIS ONLY HAPPENS IN ONE GEAR IT IS LIKELY YOU HAVE SOME DAMAGE TO AT LEAST 1 OF YOUR GEARBOX PINIONS, HOWEVER AS WHEN YOU ENGAGE A GEAR MORE THAN 1 GEAR IS MESSHED WITH ANOTHER I WOULD SUSPECT WEAR OR DAMAGE TO THE MATEING GEAR, ON THE MAINSHAFT AND THE LAYSHAFT, IT WOULD REQUIRE ENGINE REMOVAL AND DISMANTLING TO EXAMINE FOR WARE AND TARE, I WOULD SUGEST YOU DRAIN THE ENGINE OIL INTO A CLEAN CONTAINER AND EXAMINE THE OIL AS YOU POUR THE OIL FROM THE CONTAINER, CAERFULLY EXAMINE THE BOTTOM OF THE CONTAINER FOR ANY PEICES OF METAL, IN REPECT OF A BROKEN TOOTH FROM A GEAR, THE GEARS ARE MADE FROM CAST WHICH CAN BREAK WHEN WORN, IF THE OIL IS CLEAN WITH NO METAL THEN IT COULD BE IN EARLY STAGES.
The VZ 800 ,has a linkage system ,it can be adjsted to suit your needs .Firstly , your linkage attaches to the front foot lever.on the other end the linkage attaches to the actual gear box.Its this part that you need to adjust ,Undo the bolt that holds the linkage bracket to the gearbox spline. slide the bracket of the spline .undo all the adjusting screws on the linkage rod ,position the gearbox linkage unit to the required angle you need to position the foot lever to the popsition you want and the adjust the linkage rod to suit the distance between the garebox liinkage unit and foot change.
The smoke would be expected as would the temporary situation of poor performance. The grey oil is water emulsified in the oil. This probably had nothing to do with being knocked over. Normally the seals on the water pump impeller shaft go bad and leak water into the gearbox. I am going to take a guess and say the bike fell on its' left side. If so, chances are the shift lever was forced upward and the gear dogs did not line up with the next gear. This results in a bent shift fork (or two) and is $1000.00 or more to fix. I am guessing the metal to metal knocking is the dogs on a slider gear not fully meshing with the adjacent gear.
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Sounds somewhat like a bent shift fork not letting the slider gear dogs fully engage the gear. You probably have metal particles in the oil. Keep riding the bike and you will likely need major repairs. The metal particles are abrasive and thus destructive. Think of putting a teaspoon of fine sand into the gearbox. You can trash an engine pretty quick that way. I suggest you fix the gearbox now, before the top end gets too involved.