Topic: fourth gear sounds

[hymodyne]

working out new clutch disc issues on my 500K1 led me to hear a new noise in fourth after first through third shift with only minor slippage at hig rpms in third. fourth, however, makes clicking sounds that sound like they're coming form the transmission. fifth is fine, 80+.  total of perhaps 45 miles on the bike since partial rebuild and overbore.

I inspected the shift forks when i replaced my primary chain this winter, and found no significant wear on the fork selector surfaces.
also, I've had the bike up around 75-80 earlier this season and never had this issue with fourth. my adjuster base is cracked, so i've turned it 1/4 of a turn to face out a good portion of the top edge. (ala number 13's link) that adjustment is the only thing I've changes in the last day or so. I really don't want to crack this thing open again...

I'm going to hijack my own thread-

I'd like to know if in installing air fork adjusters on my K1, or specifically  if removing the threaded spacer that screws into the base of the fork nut, will negatively affect my  forks. I plan to remove it and put in pvc spacers to aid along with the pneumatic support.
by removing the threaded spacer I can drill and tap the fork nut and screw on the adjusters.
hym

[bryanj]

That threaded rod screwded into the nut isnt a spacer it holds the internal damper! If you undo it you can remove the alloy slider complete with damper and threaded rod (if you hold the bike up high enough!!) Without having to undo that allen bolt going upwards in the bottom.

Should you remove this rod and perchance pop a "wheelie" the fork alloy sliders, cpmplete with wheel and all other attached bits, can fall all the way off leaving you riding a unicycle!!!

This only applies to the K0 as the later models dont have the threaded rod and have a "stop" welded into the inside of the steel tube at the bottom such that when you "top out" the forks you get a Clunk