So, the gear change on my ST4s had been a bit dodgy before as the Gear change lever return spring has been weak, and it means that sometimes, usually going into either second or first, the lever goes down but does not spring back. Then, on track day it jammed in first gear and would not come back. On inspection, the Gear change lever pin was loose which allowed the selector drum control fork to go too far forward and it jammed between the a selector drum pin and the casing. Fortunately no damage was done. However, I now have new springs to go into it and have sorted it all out, but I do not have special tool: 88713.1091 Plate for positioning gear engagement fork This is listed to properly align the selector drum with the gear change lever. Has anyone refitted the gear change lever assembly and not used the special tool? IS it absolutely necessary, or a pro workshop time saver? Any advice gratefully received, I just want my grey ghost back on the road! Cheers, A
The tool has now been superceded by 887133334 I believe it is required to complete the job Do you have the ST4S workshop manual?
Just dug out my 996 Haynes Manual and it shows the reinstallation without the need for the tool. Sent you a PM
Right, managed to mark the gear selector drum for the centre between the two pins that are uppermost when the box is in second, as per the manual. With a bit of fiddling about, I managed to get the indexing mark on the gear selector claw centred on it as best I can and it seems to be shifting nicely up and down through the box. It's all torqued up now and it is just a case of fitting the flywheel/starter clutch assembly and then the generator cover, then the water pump, filling it full of fluids and changing the oil filter and I should be done in about two days! Update: Got another hour in at the bike, after doing daddy Taxi service for the afternoon and got the flywheel fitted and torqued using the old penny in the gears trick. Worked a treat. Have the mating surfaces of the gene cover now cleaned and all the screws laid out and I even ran a thread cleaner through all the holes just to be sure. Hopefully I'll get the gene cover on today to cure over night and fill her up to morrow and test ride it. Damn I miss the old girl! A
Success! Filled her with fluids this morning and there were no leaks. I started her up and bled out he coolant and then took her for a spin. Bloody hell, the difference was unbelievable. It must have deteriorated very gradually, because it felt as slick as a Suzuki. It engaged gears very easily and with a smooth motion. I went all the way up through the box and down again a few times, both with and without drive, and all worked well. Job jobbed as they say. A
