gear lever won't move

[maxi81]

I had my RM 400 engine rebuilt not along ago. According to my mate who put it back together it shifted through all the gears when he put it back together. I bought a gear lever for it and it doesn't want to go through the gears at all. The bike is in gear atm just not sure which one. Any feedback would be great.

Max

[oldfart]

Take your clutch cover off to see if he has put the  Pawls in wrong way round or is the shaft  missing the stopper on end of selector shaft  ( clutch side )
In other words when you put your new gear lever on did the selector shaft move inwards by 5 to 10 mm. 

[Hoony]

I reckon your on the Money Oldfart, had a similar thing happen to me once, it moved out of mesh and then jammed.

[Viper79]

Another thing to remember is the detent ball and spring are located in the sump plug.
It might pay to check to see if they are located where they should be.

[maxi81]

Thanks guys. Took the clutch cover off and found the shaft has moved across and was not lining up. I can now change gears but lever doesn't spring back after I have changed gears. Any idea on that??

[pmc57]

First up up need to know why your gear shaft moved sideways for it to disengage from the toothed segment on the selector drum. Normally the end of the selector shaft butts up against a cast in stop in the clutch cover, if this is not happening you have the wrong selector shaft.

Secondly, the selector shaft has a double-acting return spring located behind the toothed segment of the selector shaft, this spring has two legs, each leg must go either side of the pin (approx 8mm dia) that's screwed onto the r/h case. You need to ensure you spread the spring legs apart as you push the selector shaft back in to it's home position or the shaft will not return to the central position when pushed down or pulled up.

[oldfart]

You should have 14mm of past the toothed flat spot ( stopper )  early models came with a nylon stop that pressed on
If the spring is installed correctly you may have a bent shaft.

[maxi81]

I'm still having issues with my gear shift shaft. I now know the shaft moved across because I was missing a few screws from the bottom of the clutch cover and when I put the new gear lever on I gave it a few taps with a hammer and it moved acoss from where it sits. I pushed it back in place but it seems out of sync. Its in neutral and I can't put it into first as the toothed bit is hitting th case. Any ideas??

Max

[oldyzman]

Try a bigger Hammer, just kidding...

[JohnnyO]

The teeth on the end of the shift shaft are not meshed centrally with the ones on the shift drum. Push the shaft thru again and line it up properly

[matcho mick]

little tip for ya maxi,(obviously you don't know about it )tap a screwdriver into the gearlever slot,(& leave it there),just enough to spread it,makes it ever so easy to place in position on the shift shaft,then wiggle screwdriver off,bingo ,
incorectly indexed is the word you were looking for Johhny O