4th gear not there

woodrow · Post by **woodrow** » Wed Jul 16, 2014 7:40 pm

I just brought my 1967 305 scrambler CL77 out of a 43 year sleep in a basement storage. Everything is running pretty good with exception to 4th gear. When I shift, it goes though all the gears like you would expect, 4th gear feels like it snaps in place but it never actually switches form 3rd to 4th, it just stays in 3rd gear even though it goes though the 4th gear shift cycle. I have had the clutch apart and cleaned and checked it over per imformation on other post referencing clutch issues. The clutch is still very stiff to operate inspite of many attempts at clutch adjustments. I have also run the bike with a 50/50 mix of 30 weight oil and marvel mystery oil thinking that maybe the gear was not sliding into place due to some dried oil residue. No change, when I take her out on the road it will shift through all the positions but it never comes out of 3rd and into 4th gear. Could this have anything to do with the stiff clutch problem? I am sure there was no problem with the 4th gear when I put the bike away. I have search back through old post and I just don't see any history of 4th gear problems with the 305's. Anybody have a clue what I am up against?

G-Man · Post by **G-Man** » Wed Jul 16, 2014 11:33 pm

The clutch should not affect 4th gear engagement. Have you tried working through the gears without the engine running?

With the clutch basket removed, watch what is happening with the selector mechanism. Is the drum rotating properly to the 4th gear position?

You may have to get the engine out, turn it upside down and take off the lower crankcase to fix the problem.

G

woodrow · Post by **woodrow** » Sat Jul 19, 2014 11:52 am

Yes, I did try shifting through the shift pattern with the bike up on its stand and it just feels like it is going in all of the gear positions corectly. The last time I had the clutch side pan off I thought everything looked right but I guess I should pull it back off and have another look. Anything in particular I should check? Thanks Woody

G-Man · Post by **G-Man** » Sat Jul 19, 2014 12:45 pm

Just watch the selector drum and the way the detent mechanism and shifter work on the drum. If it shifts to the 4th gear position and it's still in 3rd you will have to split the cases and look at the gears themselves...

G

woodrow · Post by **woodrow** » Sat Jul 19, 2014 4:12 pm

Thanks G-Man, I am going to order some new clutch parts and I will check the shifter drum closely. Can it be removed and inspected/serviced with the engine in place? The engine on my bike is not the original. After destroying the original one when I was a kid, I bought a used engine from a local guy that used 305 engines in midget racers. I suspect he may have may have put heavier springs on the clutch pack for that application. If I have to pull this engine to work on the gears it's probably not going to happen any time soon. I will report back when I get to that point. Thanks for your help. Woody

G-Man · Post by **G-Man** » Sat Jul 19, 2014 4:35 pm

Woody

You can check the operation of the shifter drum but any corrective action will require taking the cases apart.

Good luck

G

woodrow · Post by **woodrow** » Wed Jul 23, 2014 11:16 am

G-Man, Keeping in mind that my replacement engine care form a guy that used the 305 for midget racers, could he have changed up the gears in the trans to better suit his application? Woody