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PostPosted: Thu Nov 07, 2019 3:07 pm 
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Joined: Mon Apr 10, 2017 1:12 pm
Posts: 48
Country: US
Bikes owned: T500
Alan H wrote:
The rev counter doesn't work when the clutch is in too - or the oil pump - so don't sit in stalled traffic for ages with the clutch lever pulled in!


Thanks to both Karl and Alan for that info...had no idea...that's a goofy arrangement. I wonder if anybody has damaged their bikes because of that!?!?!


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PostPosted: Thu Nov 07, 2019 3:43 pm 
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Joined: Sat Sep 05, 2015 3:14 pm
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Location: southeast pa
Country: us
Bikes owned: GT
When you try shifting, does the shift lever go through full travel or does it hit against, does it move easy or hard? you may need to pull clutch cover and make sure shift shaft arm is engaging on shift drum properly.

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71 T250 scrambler
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PostPosted: Thu Nov 07, 2019 5:35 pm 
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karl pa wrote:
When you try shifting, does the shift lever go through full travel or does it hit against, does it move easy or hard? you may need to pull clutch cover and make sure shift shaft arm is engaging on shift drum properly.


Hi Karl,
It moves, but not as fully as I would expect. It feels like it is binding at the end of the throw. It feels the same for both up and down shifting. We're pulling the cover, as you suggested, right now to check alignment and function.


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PostPosted: Sun Nov 10, 2019 8:03 am 
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Joined: Sat Sep 05, 2015 3:14 pm
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Location: southeast pa
Country: us
Bikes owned: GT
Grey_Ghost wrote:
We're pulling the cover, as you suggested, right now to check alignment and function.

Did you find any issues in shift shaft or drum, shift pawl ? If not I am afraid it could be in transmission, shift forks or gears binding. Hopefully someone else may know of something else to check.

_________________
76 GT185
77 GT250
77 GT380
76 GT500
73 GT550
73 GT750
74 GT750
71 T250 scrambler
75 T500 cafe


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PostPosted: Mon Nov 11, 2019 8:53 am 
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Joined: Mon Apr 10, 2017 1:12 pm
Posts: 48
Country: US
Bikes owned: T500
karl pa wrote:
Grey_Ghost wrote:
We're pulling the cover, as you suggested, right now to check alignment and function.

Did you find any issues in shift shaft or drum, shift pawl ? If not I am afraid it could be in transmission, shift forks or gears binding. Hopefully someone else may know of something else to check.


Sorry, busy weekend...Just got a chance to sit down and reply...

When we pulled the clutch cover, we found the shifter shaft was offset by one tooth so the transmission was always in between gears and couldn't quite finish its shift. We tapped the shaft out half an inch, re-centered, and pushed back in and it works like a charm! I was very worried something had gotten missed during assembly and we would have had to pull the motor. That would have been terrible...

We got the carbs all tuned up (Thanks ConnerVT for your carb tuning tips!!) and the bike starts on the first kick and quickly settles into a nice idle. The Higgspeed pipes sound AMAZING!

We still have a few minor tweaks and fixes here and there, but we will work those out over the next couple weeks. My son took it for its first ride around the neighborhood on Saturday and came back with a huge grin on his face! :D The timing worked out well, too, because it was also his 18th birthday yesterday.

He will get it inspected this week with his license soon thereafter. The weather here is still pleasant so he hopes to get some miles on it before the snow arrives. I will get a few pictures of it posted out in the sun this week so you can get a decent overall of the finished project.

Again, thank you all for your support, wisdom, and encouragement! We hope you have enjoyed following the build as much as we have had doing it. We couldn't have done it without you!


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