550 zephyr gearbox problem?

have used all advice given,removed engine,bits and bobs,etc.pushed a shaft through the engine lined up with the selector fork shaft covered in moly grease.the shaft was the exact same size as the fork shaft and picked up all the selector forks etc.the gears were then soaked in oil and the shafts turned,the gears could be selected.the original fork shaft covered in moly was fitted and gears are ok.engine is now back in frame and runs sound.cheers for your help lads.

550kwacker
June 2010

was given the bike for the missus.no not a swap.it was stood for six years uncovered so was a mess.stripped it down because sadly i enjoy it. have removed the engine from the bike again on the bench gears can be selected 1 to 6 then they cant.wondering if its just a lube problem.have noticed when its hard to get gears the shaft with the selector forks on becomes very stiff.all parts were checked with a micrometer and are sound.

zr550
May 2010

you need to take the clutch cover off and pull the clutch off then tale the gear lever off then pull the selector shaft out and then try and turn the end of the selector drum with the allen bolt in the middle of it and see if it will turn easier.you will need to spin the counter shaft with your fingers while you try and get a gear.counter shaft is the one the clutch was on by the way.

adam bike doctor
May 2010

Its strange that you could find all the gears while the engine was on the workbench, ie not running (I assume) and without the use of the clutch?! was the gearbox re-filled with oil after the rebuild? why was engine re-built, had it done high mileage? if so, were the gearbox internals measured/checked for wear such as excessive end float, chipped teeth, bent selector forks. Has the gear selector shaft had a knock and is tight in the casing. Maybe somethings been left out or not indexed properly, sounds like another tear-down to find out.

Chris P.Duck
May 2010