Control Rod not moving

[viclioce]

OK. I put the newly rebuilt control rod/counter shaft assembly back in the transmission. But, every time I close up the cases, the control rod won't move in and out. I've tried it with the control rod pushed all the way in, (5th gear I believe) & with it pulled all the way out (1st gear?).

It moves freely when I have the shaft out of the case, or mounted into the right side case with the left side off. But the minute I get the left side half of the tranny bolted down, the control rod won't move others than a slight bounce of the springs. So it won't shift through the gears!

Can anyone tell me what I'm doing wrong! I am doing it the reassembly as per the shop manual!!! Thanks!

[Bullfrog]

Try again while rotating the mainshaft or the counter shaft. The gears inside MUST be turning to allow things to rotate into proper alignment to allow the ball receiver to move out of the "lock" position. Gear "release" and "next gear" engagement requires gear rotation/movement.

Ed

[viclioce]

So Ed, are you saying that if I put it back together (in which case I can't rotate the gears) that when I start it up I shouldn't have any issues? That's fine if il this is a correct statement. Maybe just depressing the kick shaft will move things enough?
I just don't want to keep screwing things up and having to resplit the cases over .& over again! -Victor

Edit: I guess I can put the main shaft gear on and turn it that way, before reinstalling the clutch basket???

[Bullfrog]

No. What I'm saying is that when the cases are put back together, the gears should turn freely AND that you need to rotate the gears to allow the control shaft to move "in" and "out". If the gears are not rotating/moving, you will find situations where the control shaft can not be moved in and out.

So . . .

MAJOR PROBLEM = cases assembled and gears will not smoothly and easily rotate. (do not pass GO and do not collect $200)

Procedural problem = cases are assembled and gears will rotate smoothly and expecting the control shaft to move through it's complete travel without rotating the gears. (change the procedure . . . rotate the gears while testing to see if the control shaft will move in and out).

Ed

[viclioce]

OK Ed! I follow you. I will mount the big gear on the main shaft and see if I can turn the gears and move the control rod! S
; ) Victor

[eichco1]

Which model Hodaka are you working on?
The shop manual gear stack doesn't apply to the 03 Wombat, or the Dirt Squirt 80.

Mark in Illinois
#492

[eichco1]

Another item to check is to make sure the counter shaft bearing in the left case half is fully seated.
If it's not, it could bind up the gear stack. Been there, done that.

Mark in Illinois
# 492

[viclioce]

Mark. I have a Frankenbike! LOL! It consists of a 1976 Model 03 frame/rolling chassis, with a Model 94 bottom end and a model 95 top end. I can confirm the bottom end by the serial number on the casing. the top end I confirm by the exhaust port and gasket required.

I just got new seals and bushings for the bike. The one sent to me for the countershaft in the right side of the case didn't fit the shaft. It wouldn't spin. So I had to put the old one back in. Then the shaft would turn. I didn't get outside today to check and try Ed's recommendations but will do so tomorrow and see if I get positive results. I confirmed with another forum member that the shoulders all go to the left facing the counter shaft sprocket and installed them that way. So, as far as I know they are all in correctly, yes??? - Victor

[shunt]

Victor I found the same issue with my Model 96 Dirt Squirt when I fitted a new counter-shaft bushing in the right side casing, I put it down to either the bush had closed up after being fitted (I heated the casing up in the Weber to a point of the bush being a tap fit) or possibly some miss alignment in the casings from manufacture.
The above aside, I brought a set of adjustable Reamers out of India on Ebay, gave said bush a couple of thou of extra clearance and all is sweet and I now have a set of adjustable Reamers!
Shane

[eichco1]

Frankenbikes, or as I call them, "bitsa bikes", are some of my favorites.
I have a couple of them myself.

Yes, for the 94 transmission, all shoulders to the left. I assume this transmission was assembled when you got it. Another thing to look out for is using the proper gears/kick starter gear when sorting through a box of parts. Unless you count the teeth, they all look the same.

Mark in Illinois
#492