Clutch / gearbox issue - No 2nd gear upwards

[Panos]

Do you mean the gears shifted fine BEFORE assembling the transmission into the engine cases, or they worked fine AFTER assembling into the cases?

yeap, replaced the clutch and gearbox while engine was sitting on the floor and all gears were present, I shifted from 1st to 6th and back to 1st again.
Put the engine on the frame/bike, lost 5 gears!

 

[pbbanks]

Do you mean the gears shifted fine BEFORE assembling the transmission into the engine cases, or they worked fine AFTER assembling into the cases?

thought the 1200gs has a seperate gearbox as a unit so you don't assemble the transmission into the cases. It's just a gearbox unit swap.

 

[Pukmeister]

thought the 1200gs has a seperate gearbox as a unit so you don't assemble the transmission into the cases. It's just a gearbox unit swap.

Its like a cassette gearbox, unlike the hexheads that are separate.



If the gears worked prior to putting the engine back in the frame then surely it can only be frame/gearlever related and my previous assumption about internal issues is incorrect ?

 

[lucas]

Had this problem on mine. You probably haven't put the linkage back on the gearbox splines right and its catching on the final drive cross section.

 

[Panos]

Had this problem on mine. You probably haven't put the linkage back on the gearbox splines right and its catching on the final drive cross section.

I will have a look when I get home from work - thanks

 

[Panos]

Problem solved! The clutch pedal linkage was actually causing the issue! I loosen up the bolt holding the linkage, and the arm slided a bit out.. suddenly all 6 gears are there! Success

Can someone take a picture of the linkage just to see how deep the arm is sitting inside the small shaft!

Thanks all for your replies!

 

[pbbanks]

have you got it on the wrong way round or something??. It should fit flush with end of the shaft or there abouts usually. Yours looks a long way out from end of shaft. Mine has gsap so cant compare. Or is the arm too far round anticlockwise on the shaft?? think the slit on the arm where the bolt goes through should be inline with the groove across the end of the shaft. You have it sorted anyway and changing gears so fine tuning now.
Heres a link to anothe post with photo of shaft and arm :-- https://www.ukgser.com/forums/showthread.php/351676-2013-2014-LC-gear-shift-Linkages
it has a quick shift but arm looks standard.

 

[Panos]

Here's some more pictures, the arm's bolt is at the rear so I am sure this is installed ok. Got it sorted at the end, just moved the arm slightly outwards and retighten the bolt, all working fine now!

Also a couple of pictures of the broken gearbox output shaft

 

[pbbanks]

glad it's sorted, well done for tackling it. OUCH with the output shaft. Didn't the drive shaft give any indications it was on it's way out before breaking, like knocking or vibrating. Guess the needle rollers in the joint wore out and then the joint broke & jammed the shaft.

 

[Neil W]

Just checked on my non gsap sub 100 miles old 1250 and that looks right, the end of the shaft does not sit flush with the outer edge of the shift arm , the pictures of the arm on the broken box looks about the same as mine ,if yours is working as you now have it set I would leave as such

 

[Panos]

glad it's sorted, well done for tackling it. OUCH with the output shaft. Didn't the drive shaft give any indications it was on it's way out before breaking, like knocking or vibrating. Guess the needle rollers in the joint wore out and then the joint broke & jammed the shaft.

I was feeling the bike vibrating throught the foot pegs but didnt really pay attention..

 

[Panos]

Just checked on my non gsap sub 100 miles old 1250 and that looks right, the end of the shaft does not sit flush with the outer edge of the shift arm , the pictures of the arm on the broken box looks about the same as mine ,if yours is working as you now have it set I would leave as such

thanks for confirming Neil!

 

[Winjar]

I was feeling the bike vibrating throught the foot pegs but didnt really pay attention..

good picture below in link from Mr ding dong shows good linkage post 3

https://www.ukgser.com/forums/showthread.php/351676-2013-2014-LC-gear-shift-Linkages