4th gear issue

[shane BBoys]

Evening.
I finally got a chance to take the S2 for her maiden run: I couldn’t get 4th any ideas? There seams plenty of room between the rear and the gear selector arm!
Cheers Shane.

[al pushpak]

2/3/4th gear cable too tight ?

[bookertmgs1]

Have you checked that the gear arm is on the shaft on the correct spline ? Should level up to the side case stud when in 2nd gear. I had same issue and found out I was a spline out when I started to investigate. Was certain it was correct when I assembled the engine.

Assume that the gear housing had free movement at headset when assembled.

Checked back brake cable routing

[missing lynx]

Have you used a new tie rod? As some are the wrong length eye to eye

[shane BBoys]

Have you used a new tie rod? As some are the wrong length eye to eye

Yes it is a new 1 I’ll check the length.
Cheers Shane.

[shane BBoys]

Have you checked that the gear arm is on the shaft on the correct spline ? Should level up to the side case stud when in 2nd gear. I had same issue and found out I was a spline out when I started to investigate. Was certain it was correct when I assembled the engine.

Assume that the gear housing had free movement at headset when assembled.

Checked back brake cable routing

I’ll check all the above.
Cheers Shane.

[shane BBoys]

2/3/4th gear cable too tight ?

Thanks I’ll check.
Cheers Shane.

[Toddy]

Try selecting the gears without cables connected by hand see if you can get them all

[Covboy]

I had this once . I had thought I’d selected neutral between 1st and second when setting up the cables / handle bar selector, but I’d found a false neutral between 2nd and 3rd. When I thought I was in first , it was actually 2nd and I couldn’t get as far as 4th .

[shane BBoys]

Today’s findings:
The selector arm was 2mm in difference, so I removed the coating from with the trunnion hole, I removed the rear wheel and while the bike was on the engine prop I gingerly kicked her over, it stayed pretty firm so I pulled the clutch in with the left and operated the gear arm with the right, and found all the gears, I popped her in neutral and put the wheel back on and re- cabled the selector, I’ll try over the weekend hopefully all your answers have got me where I need to be.

Muchos