harps2 wrote:Well finally put her all back together with new shims, checked all gears for any wear/damage everywhere and managed to increase size of gearbox shim to reduce clearance - Guess what ---....
STILL THE BLOODY SAME !11
the noise only goes away when you PULL CLUTCH INN AND SELECT GEAR - let clutch out and noise returns.................................
Warkton Tornado No.1 wrote:If the noise disappears with clutch pulled in & gears engaged, then the problem is most likely within the gearbox area.
My suspicions would be:
something is catching on the first gear or the inner clutch top plate (typically the kickstart) or;
the gears are noisy through too much clearance, a mismatch of gears or a broken tooth/teeth.
If it isn't that & you have the correct shimming to give as close to 0.003" as is possible, & the gears are not missing any teeth, then you should check the only things likely I believe to be remaining, which are mismatched gears (Sticky's book has number of teeth & outside diameter), a bad endplate bearing/journal/lay-shaft journal or the cursor itself.
We all sense your frustration, but if the noise disappears with the clutch pulled in, whilst in gear, that puts all four ratios under a slight load due to the dragging of the clutch. That will cause the quietening of any noisy gears.
Although I would still tend to call the problem "mismatched gears" it was not especially helpful if all you have to go on is the number of teeth & outside diameter by which to check! So, I apologise but will endeavour to try & help:
The problem you have will most likely be due to (especially) "brand new" gears that are manufactured badly & therefore badly mesh. All gears have a curved face (profile) that should conform to a "pressure angle" & any slight deviation will result in "ringing" which results in a noisy gearbox.
Likewise, all gears are produced to a PCD (Pitch Circle Diameter) that is the true diameter which meshes with the true diameter of another gear. So, even if the profile (mentioned above) is correct, if the PCD is incorrect &, say, undersized, the result will be an incorrect mesh with too much clearance with the gear it should mate with.
Where might all of this conjecture leave you?
The best way to find out is to borrow another complete 'quiet' gearbox of the same type & substitute it completely, or gear by gear until you find the likely culprit.
I have no idea of how feasible that may be for you, & how helpful it is to mention that I have a considerable amount of gearboxes (especially TV200) but if I can help, I will.