I'm new here but I just rebuilt my 77 DT400. New wiseco piston, boyeson reeds, new mikuni 34mm carb, penton ignition.

my shop tells me there are a couple 'tricks' to assembling the crank case so it works properly.  I have three manuals

to work from...didn't see anything out of the ordinary. this is my first bike rebuild. 

I assembled it in neutral and now it is 'stuck' in neutral...it runs but won't go in gear.

should it have been assembled with the 1st gear cogs engaged? the shift cam slid the forks okay in halves.

what did I miss????

mrcbody 

 

Hi mrc" , , have you built it, [joined cases,]  . theyre simple enuff gears,   .have you got the side casing on , [ clutch cover,[ as you may have pushed the gear shift shaft thru. and the selector teeth on the pawl slipped out of line,  thus as you try to select gear, the pawl jams against the bottom of case,

 

Hi blackhat,  I recognize the shaft of which you speak.  I re-used the E-clip that came with the shift lever

and saw it lost its temper(hardness) if it ever had any. (the service manual says to replace the clip when servicing)

I re-crimped it and it 'popped' off in the side cover.  The shifter pawl did come apart then.

I have since re-assembled everything with a new 'hardened' clip but somehow it is still stuck in neutral?

the pawls are lined -up but it seems jammed...the shifter stresses against the 'finger' type springs.

the cam won't actuate from the shifter linkage.