My kickstart is sticking down on occasion and sometimes not engaging with the pawl's every time. I want a look inside, got the outer cover off, but the inner moves slightly but then sticks. Do I have to strip the clutch to get into the gearbox?
The photo shows current progress.
Inner cover removal.
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Cover removal is..
Covered in the gearbox section of the manual, as attached:
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Threads
All of the gearbox studs and nuts have right-hands threads except for the rear chain sprocket nut/shaft. This is better known as the Sleeve Gear. The gearbox Mainshaft passes through the Sleeve Gear and has right-hand threads at both ends.
As follows is very handy Trouble Shooting Guide........
GEARBOX TROUBLE SHOOTING GUIDE
Symptom Cause
Kickstart lever does not engage. - Worn kickstart pawl
Kickstart engaging under load. - Worn lay-shaft bearing in Shell or Broken Lay-shaft
Cannot engage 1st &/or 4th gear - Incorrect meshing of quadrant with the cam-plate
Engaging false neutrals - Incorrect meshing of quadrant with the cam-plate
Difficulty shifting between all gears - Bent mainshaft or bent layshaft
Difficulty selecting gears - Selector spring upside down or broken (weak)
Gearbox will shift up but not down - Return spring broken
Gear lever will not return to mid position - Broken return spring
Jumps out of 1st gear under load - Worn engagement holes in lay-shaft 1st gear
Loss of 1st &/or 2nd gear. - Broken lay-shaft
Grinding noise in 1st gear under load - Broken lay-shaft
Loss of 3rd &/or 4th gears - Worn mainshaft bearing in inner cover
Whine in lower gears - Worn bush in kickstart axle
Cannot engage neutral when bike is stopped - Clutch needs cleaning &/or adjustment;
- or incorrectly adjusted primary chain;
Loss of clearance between sprocket and shell - Sleeve gear bearing loose in gearbox shell
Grinding &/or chattering noise under load - Broken gear tooth / teeth
Sloppy gear selection - Too much mainshaft &/or lay-shaft end-float
- or worn thrust washer (Lay-down only)
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Greater experts than I have…
Greater experts than I have posted here...but surely the original question was: must the clutch be removed before removing the gearbox inner cover? Surely not?
(Edit...sorry Ian...you did answer...I ought to go back to sleep...)
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I got into it!
Thanks David, but I got into it without touching the clutch. Removing the clutch operating arm housing revealed a nut on the idle shaft. Removing that nut allowed me to get at the kickstarter mechanism.
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If you remove the clutch actuating arm you will see the nut on the end of the main shaft. This nut needs to be undone before the inner cover can be removed.