1995 Moto 4 350, not shifting properly

[KdlH]

Following on from this thread;

 

I've finally got around to pulling the clutch cover off to have a look at the shifter ratchet mechanism. The screw holding the pinned star wheel has come loose and the wheel flops about. Unfortunately the keyway on the shifter cam has broken on both sides, I found both pieces.

Anyone had this problem?

The keyway on the cam "ramps" out, so I'm thinking of making a slightly longer key with a ramp ground into it. I'll put it back together with retaining compound. It may not work but I think it's worth a try.

 

 

[AnthonyT]

I've never had this happen to me but it sounds like you are confident in your abilities! I say go for it. Good luck and let us know how it went!

[Mech]

So you just need a key and bolt it back together ? It looks like the seat where the star washer sits or the shift drum is a bit worn ? As long as the washer sits nicely on the shift-drum again it looks like it should be ok.

And yes I've seen the bolt loose, and those pins the ratchet works on can come out in some bikes. It's good nothing got down into the sump.

[Gwbarm]

I have seen this happen more often than it should. Yes, put it back together if the washer still fits good on the broken end of drum. Also put red locktight on it, but if you ever need to get it off again you have to heat it up to melt the locktight.

[KdlH]

Thanks AnthonyT! Yes I'll let you know if it works!

[KdlH]

14 hours ago, Mech said:

So you just need a key and bolt it back together ?

Yes I've bought some 4mm key steel.

Yes it is a bit worn as well. It really is very hard up but I'd rather not split the case if I can get away with it. 

13 hours ago, Gwbarm said:

I have seen this happen more often than it should. Yes, put it back together if the washer still fits good on the broken end of drum. Also put red locktight on it, but if you ever need to get it off again you have to heat it up to melt the locktight.

I was thinking that a larger screw might have held in on there a bit better.

Yes I'll use threadlocker on the screw and retaining compound on the shaft and keyway.

[Mech]

Well it's steel at least.. A high grade bolt with a flange under the head, done up real tight, will keep it on hopefully.

[KdlH]

I took a video of the movement before I removed it. https://youtu.be/T83MB9f0dYA?si=zNBbrbzu8d0kqVxk

[Mech]

Hmm. Hard call. I'd say if the back seat was flat so the washer gets held between two flat surfaces, being the shift drum's flange and a flange headed bolt, then the play on the locating part will probably be ok with a bit of loctite or maybe nothing. If the flat part's damaged though it may struggle to stay solid..   I'd just give it a try and monitor the action before I put the cover on. If it's not moving on the shaft it'll probably last. If there's the slightest bit of movement, it's doomed..  haha

[KdlH]

I made a longer key and refitted the wheel with retaining compound and thread lock on the screw. I'm reasonably confident it'll hold. I left it for a few hours and then tested it while the cover was still off. It now goes through all the gears so I'm happy with that!

 

 

Do you know what torque the cover bolts should be?

Thanks

[Mech]

Nope. But one more post and you can download the manual..

 

[Gwbarm]

Should be about 10-15 ft pds.

[KdlH]

 

10 hours ago, Mech said:

Nope. But one more post and you can download the manual..

 

Haha, right ok!

4 hours ago, Gwbarm said:

Should be about 10-15 ft pds.

Ok thanks