Kioti Paul
Silver Member
"I took the next layer off and removed the "forks" and both of them slide independently. When one goes up or down the other is locked into position. The "balls" that they lock onto in the 2nd picture do not move freely. the bottom one jiggles for and aft but the front/top one does not"
This seems like a very unusual transmission! Usually the cluster gear is on bottom, and the sliding gears on top. I may not be looking at it correctly, but it seems like the forks go down into the trans oil, and the sliding gears are completely under the oil. I think the "balls" you mention are the upper most part of the forks (the rest of the forks are below the oil and are not visible)
It sounds like you are saying that in the "layer" you removed, the two shafts do go back and forth freely, and that the lock out function is working also.
The "balls" (forks) should slide freely on the shaft; and it sounds like you are saying that at least one of them (forks) is not. If it were me, I would begin by draining the oil so that I could see into the bottom of the transmission. It should be relatively easy to determine if the fork is 'bound' to the shaft, or if it is the sliding gear that is binding on the splines.
This seems like a very unusual transmission! Usually the cluster gear is on bottom, and the sliding gears on top. I may not be looking at it correctly, but it seems like the forks go down into the trans oil, and the sliding gears are completely under the oil. I think the "balls" you mention are the upper most part of the forks (the rest of the forks are below the oil and are not visible)
It sounds like you are saying that in the "layer" you removed, the two shafts do go back and forth freely, and that the lock out function is working also.
The "balls" (forks) should slide freely on the shaft; and it sounds like you are saying that at least one of them (forks) is not. If it were me, I would begin by draining the oil so that I could see into the bottom of the transmission. It should be relatively easy to determine if the fork is 'bound' to the shaft, or if it is the sliding gear that is binding on the splines.