XT600 gearbox rebuild

[thepom]

So trying to rebuid my tenere gearbox,the old shorter kickstart gearbox transmission works fine but when I put the electric start transmission in the casings it jams up.

I,ve measured everythng and for the life of me can,t figure out whats wrong.

Any one with gearbox experiance out there got any idea,s for me....cheers

[Grumph]

When each shaft is put in place individually will they spin freely ?
Does binding only occur when both shafts mesh ?

[thepom]

Hi Grumph,yeah each shaft turns on its own but together they bind. I have measured both shafts and can,t see any problem.

[Grumph]

Three possibilities
One of the free running gears on either shaft is partially seized
or
The different model has a different shaft spacing - center to center
or
the shift forks (you are trying it with them in ?) have slightly different profiles between the models.

There can be subtle differences between what look like the same motors used in different models.

[thepom]

Cheers mate,will have another look tonight...