trans stuck in gear please help

ridingtx500

ridingtx500

New Member
just finished rebuilding the engine and trans in my yamaha tx500 restoration project. went to take it out for a test ride, engine runs great but trans seems to be stuck in 3rd or 4th gear. clutch works fine. where did i go wrong and must i remove the engine and tear it all back down and start over.
 
ouch.. when you started the bike for the first time did you have to start the bike with the clutch in a and hold it in?

is the shifter stuck or is it "flopping in the wind" loose?
if the shifter is working, it wont shift with the motor off by rolling the bike forward and back?
Did you try to get it going down the road in whatever gear it was?
 
engine started right up, did not have to hold clutch in
shifter seems fine not loose, pushed shifter down once for 1st gear tried pulling out and bike bogged down like it was in high gear, put it back in neutral tried again same thing.
did not try taking it down the street
 
If you can definitly find neutral indicated my the neutral light then i cant imagine going down to first would put it in any other gear then first.. perhaps timing or carbs are need to be tuned.. i would try slipping the clutch till you can nurse it up to speed just to see if it is first and the bike has trouble under load or if it is a trans problem
 
thanks
i will try taking the bike down the road, beats tearing the engine back out and a complete tear down
 
Did you have the shift drum/forks removed? If so, was it cleaned? These things can get pretty sticky if they aren't *lightly* greased upon reassembly. If the gears don't move, dont force them or youll be looking for shift forks as well...
 
i removed the drums cleaned them and lightly coated them with stp oil treatment after i reinstalled the drums.

any ideas on how to free them up

thanks
 
That may not be the issue(then again, it might). Did you run the transmission through the gears before you reassembled the cases? When you say "rebuilt transmission", what was entailed? Just a re-shim or new gears as well?
 
i removed everything out of the transmission case, cleaned everything then reinstalled and tried to make sure it shifted through all the gears.
 
I'm just ruling out the possibilities
Did you remove the forks from the drum?
Are you sure they were assembled in the right order?
 
did not remove the forks from the drums
when i removed everything i layed it out on a bench in order so i would not screw up reassembling
 
stumped
well, somethings bound up. no question about that
one solution at this point: teardown and split cases
sorry to be the bearer of bad news
good luck and hope you chase it down
 
yeah, dont take anyone's opinion over the net too seriously. Thats why most old timers wont say a word about it unless they have it in front of them
 
Check shift mechanism first, it could be assembled wrong or catching on something.
I haven't done one for a few years and can't picture it to give better advice
 
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