4 speed popping out of gear??

[twigs76]

I have a 1972 T100 that keeps popping out of 3rd and 4th gear. Can anyone explain the problem to me?

 

[grandpaul]

Might be a worn gear selection camplate and/or selector pawl wear.

 

[twigs76]

Might be a worn gear selection camplate and/or selector pawl wear.

That is how I feel after all the research I have done, the popping out of gear, the false neutrals, and hard shifting. I have the outer cover off, however, after removing the 2 retaining screws and the nut on the inner cover, I can only pull the cover out a few inches as if something is still holding it. I have the bike in 4th gear. Today I am going to remove the primary cover on the other side. I think there is something retaining it from that side as well if I understand what the manual is telling me. Are camplates and selector pawls readily available? Also, am I on the right track? Any little tips or tricks would be greatly appreciated.

 

[Rocky]

You have to dis-assemble the clutch system on the primary side and remove the locking nut to withdraw the inner gearbox cover as it and all the gears come out as a complete assembly on the right side.
The parts you mention should be readily available from most any good parts dealer, but you may have to search the internet for availibity - or simply email the dealer.

 

[twigs76]

Might be a worn gear selection camplate and/or selector pawl wear.

I completed disassembly and found the camplate and selector pawls to be ok. After looking it appears that the kickstarter shaft and the gearshaft became separated. In the picture you will notice the bushing has come out and also the damage to the ear that is on the the shaft also. There was also some scaring on this surface where you could tell that there was separation. Trouble with the kick start engaging and returning kind of confirms this in my mind. Any suggestions on what parts to order and where to get them?

 

[grandpaul]

All you need to do is determine the part numbers of the damaged bits, and you can get prices and replacements from any reputable parts stockist.