Hopefully thats my false Neutrals sorted
 

For the last couple of rounds at Anglesey and Oulton I have been surrering a few gear shift problems, namely when trying to change down from 6th to 3rd in a short distance, such as the run into the Shell Oils hairpin and no doubt it would also have been a issue into Park in a couple of weeks time.

If I did try changing down 3 gears in short succession I would let out the clutch and find I was in a false neutral between 2nd and 3rd gear, where the selector drum had over shifted. Going down another gear results in a locked rear wheel so if it happened it was a case of shifting back up a gear into 3rd

I did think about just trying to adjust it but decided to buy a replacement gear selector first.
Well today I stripped the Alternator casing and the flywheel off and removed the gear selector and this is what I found.

Bet your glad it was just the selector arm and not a split the casings senario. :eek:

If I had to go that far Neil it could wait until the winter, quick fix would be to either chuck one of my other engines in or use the Wet bike :)

Hi Kev,Mine does that sometimes but its 5 speed,Is it the same assembly?
Where can i buy that part if thats my problem please?

Hi Brian, yep should be the same part, I bought mine off Ebay although it was was from a 800 Monster S2R, I went for the newer the bike the better as less likely to have suffered to much wear also a bike not likely to be hammered around a race track

Great photos, any chance of a simple explaination of how it works?

Probably easier to explain at Cadwell

But in brief the claw part that sits at the top of the selector drum pulls the dogs on the drum either left or right depending on which way you are shifting, this rotates the drum moving the gear selector forks.
The limit of each shift movement is goverened by the part that sits in the centre of the drum hitting the wall of the drum and preventing futher movement.
In my case the bit that sits in the centre of the drum had one edge broken which caused the claw part to travel to far on down shifts, hence over rotating the drum and moving the selector forks to a position where they didn't engage a gear, more often than not it was in a position between 2nd and 3rd gear

Hi Kev,Many thanks for your reply,I stripped it today and found its actually perfect ? no damage or significant wear visible, I suspect im just trying to change down to fast and not allowing it to centre before going again so to speak
Will try to change technique for cadwell and see how it goes
Thanks again for your advice

Neither my 583 or 620 have ever allowed more than 2 gears at a time, and often more than 1 between clutch dips especially end of a session

Brian while you had it apart did you check it was all centred OK as there are two points of adjustment