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Join Date: Jan 2011
Location: Smack in the middle of Illinois
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Although all the gaskets are new, do not reuse the gasket between the crankcase halves or the head gasket - I personally will not reuse the cylinder base gasket - the other gaskets can be reused (if you want to) because they are rather easy to change down the road.
Tip from the pro: when the crankcase is together and the shift drum lock is installed; snap a vice grip lightly onto the counter shaft (where the engine sprocket rides), put the shift lever on the shaft (any position is fine and it does not need to be tightened (unless it is worn and slips)), turn the input shaft (where the clutch mounts) with your fingers (or put the inner clutch hub on the shaft for greater leverage) - while turning the input shaft, operate the shift lever - each operation should result in the selection of the desired gear - Note, the gear may not engage fully upon operation of the shift lever, just continue to turn the input shaft - when the engagement dogs line up, the transmission will click into gear - shift through all the gears once or twice to verify proper operation - if there is a problem, it's easier to attack at this point instead of when the engine is completely together and running.
Also note: most people do not shift constant mesh transmissions properly. Most people are familiar with synchromesh transmissions used in automotive products. In the synchromesh transmission, the engagement of the gears is facilitated by a pair of sychro gears that fit inside the power transmitting gears - the two 'sychro' gears are used to spin the chosen gear to the same speed as the drive line so the gears will align and engage - the common sequence of shifting is; disengage clutch, operate shift lever and engage clutch. For constant mesh transmissions that sequence is WRONG! - it may get the job done, but it can result in transmission damage. The proper method of shifting is to disengage the clutch, operate the shift lever (either up or down) and hold it, engage the clutch and then let off the shift lever. Under racing conditions, the clutch is used to modulate the power to the drive wheels and shifting may be accomplished without the use of the clutch - the engine speed is simply increased or decreased to remove driving force from the transmission shafts and the shift is initiated - once again, the shift lever is held in the direction of the shift until the driving force is reapplied - holding the shift lever assures the gears engage when the driving force is applied - if the engagement dogs do not engage fully before power is applied, the engagement dogs may simply skip over each other (missed shift) or may engage violently - both occurrences may result in gear damage.
Let me know how it goes and what you find the problem to be.