Topic: CB550 Trans Gears Stuck

[drkblusea]

Hey there.
I’m currently reassembling a 1976 cb550f engine. I’m in the process of assembling the transmission gear shafts in the case. I have meticulously assembled each shaft using online videos, shop manual, clymer manual, etc. I am confident that I have the gears in the correct positions and all clips and spacers are correct. Shift drum and forks are verified reusable and installed correctly. However, when trying to roll through the gears to check before mating the two case halves, the shafts always hang up after about one rotation. I had to purchase a donor eBay transmission to replace two broken gears. Are these gears meant to be used only in pairs and can’t be mix matched? It won’t let me upload a video. But imagine that no matter the gear you are in, the main shaft will only rotate around about once before sticking and neither shaft wants to move.
I have tried everything I can think of and verified everything countless times. I’m at a loss. Thankyou in advance for your help.


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[bryanj]

I remember there was one gear ratio where the tooth profile was altered and the mating gear had to be replaced as well.
What i cant remember is wether it was 500 or 550

[dave500]

the 500 and 550 only share third gear,all the rest were changed in some way with larger dogs and bronze bushings etc,take it apart again and retry,its possible to get the pair of forks on the separate shaft the wrong way around,check that first.

[drkblusea]

I remember there was one gear ratio where the tooth profile was altered and the mating gear had to be replaced as well.
What i cant remember is wether it was 500 or 550

Thankyou for you’re input. I ended up finding that the countershaft second and third gears that mesh with the mainshaft second and third gears are mated together as far as tooth profile. I just had to try the different ones I had together until they meshed properly and allowed the trans to fully shift through all gears.
Thanks again!


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[drkblusea]

the 500 and 550 only share third gear,all the rest were changed in some way with larger dogs and bronze bushings etc,take it apart again and retry,its possible to get the pair of forks on the separate shaft the wrong way around,check that first.

Thanks so much for your input. I ended up finding that the countershaft second and third gears that mesh with the mainshaft second and third gears are mated together as far as tooth profile. I just had to try the different ones I had together until they meshed properly and allowed the trans to fully shift through all gears.
Thanks again!


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