1972 450 engine questions

A couple more. It looks to me like the 4th gear shift fork is getting cooked. That fork moves the 5/6 gear pack by the book.
I'm not understanding what the problem is as the 4th gear pressure line doesn't look like it should be affected by the 5/6 pack. also the alignment of the 5/6 pack to the other gears doesn't look right like they are not full on gear to gear.

Ouch! Damage looks substantial. Its difficult to get a good view of whats happening with only close ups. Did you notice if the gears where lining properly after it was assembled? After getting the new drum did you check it next to the existing one to make sure all the roller channels were the same?

suummat's not rite....

Pics of each gear above the case1st 2nd 1st,neutral,2nd,3rd

4th,5th,and6th click on the pics fast to see the movement, if there is move movement.

Looks like they don't line up with each other straight on, like they only engage half way. I'm confused as to why they don't line up squarely. This trans was in the motor when I got it, maybe that's why I got it! The gears are not the original part numbers for the 76 250 250 trans, so maybe that's the problem. I'm gonna have to pull the clutch and make a jig so I can understand what's going on.

Can't beat a Suzuki TS series bikes back then. The quality was there for a dual sport.

Looks like you are missing the little roller that fits on the guide pin on the shift fork.

Marty

I have the roller. Pics are mocked up after initial teardown. I have some plexi 1/4" i'll use as center cases to see what's going on.

Here's the plexi mockup, a couple of hrs more and it will spin freely and I'll have all the washers and detent for the shift shaft installed. We'll see.

A couple more.

That is brilliant!

The Zep did not care about DUAL Sport cycles... Dual sport probably meant something else to them. Hahahaha

Sorry for the last post... Please enjoy the zen.

From my limited perspective while the trans is in fourth gear the gears associated with 4th are where they're suppose to be. However I do see 3rd gear is out of alignment. I don't know that 3rd has anything to do with 4th not engaging.

It hard to say whats wrong not knowing if the shifting fork rollers are in place and other details like shims and spaces are in their correct places.

Check out the attached 6spd gear position chart. It works best to flip it 180 when comparing 4th gear to your photo.

Please understand , I posted these pics because this is pretty cool. THIS IS NOT a working model at this time, it will take a little more time to finish. Shims, detent and other considerations are missing. Crash how do you post the pdf's. I could not figure that out or you would have seen it in post #101. Thanks for the help.

Choose the Upload a File button at the bottom.

I tried to right click part of the page and insert it and it came out HUGE. Anyway looks like the drum is incorrect, in the video you can see the output shaft 3rd gear is not all the way into the outside 2nd gear preventing the 5/6 set from moving all the way over to the main shaft 3rd gear....I think.
View: https://youtu.be/2YfaeoLbLPk

Here's the 4th gear video.
View: https://youtu.be/uNHJXA7KvuA
I have no idea what is happening here.
I need to study this a lot more, maybe the shift forks are in the wrong position.

To test this theory try the stock drum to see if it resolves the problem.