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The KH 400 Gearbox

Posted by Andy C <iframe src='https://members5.boardhost.com/classicbikemart/info/user=Andy+C' width='330' height='300' border=0 style='border:none;'> on November 17, 2024, 6:54 pm

Managed to source a "fair condition" complete gearbox from E bay which arrived on Saturday.

It does indeed appear to be in fair condition, the gears that really needed re bushing in mine are much better than mine were. Just a little movement but not enough in my opinion to warrant re bushing.

The "fair condition" one had a knackered output shaft bearing so I pulled the good one off mine and fitted it to the new shaft.

I pulled everything apart - took every gear, shim and circlip off the shafts to check that everything was assembled correctly, and that nothing was too badly worn. As far as I could ascertain everything is in good order.

I have just ordered new circlips for the gearbox shafts, the guidance from Mother Kawasaki is never to re use the circlips on the gearbox shafts.

Only downside is that the bearing on the gearbox "input shaft" is a sliding fit on the gearbox shaft, on the old one it was just discernably loose, I plan to re assemble it using Loctite 620 (high strength / high temp) which should hold things together.

Temporarily put it all back together this afternoon just to check that all gears select, and they do.

At the end of the day my old gearbox cluster will be "retired" and probably find it's way onto E Bay once the bike is back up and running.

Who needs a signature anyway......

Re: The KH 400 Gearbox

Posted by JERRY <iframe src='https://members5.boardhost.com/classicbikemart/info/user=JERRY' width='330' height='300' border=0 style='border:none;'> on November 17, 2024, 9:42 pm, in reply to "The KH 400 Gearbox"

Well done Andy hope it all goes back together and works as it should do.

The oldest rocker in town!

Re: The KH 400 Gearbox

Posted by geoff the bonnie <iframe src='https://members5.boardhost.com/classicbikemart/info/user=geoff+the+bonnie' width='330' height='300' border=0 style='border:none;'> on November 17, 2024, 10:11 pm, in reply to "Re: The KH 400 Gearbox"

Should work very well with your expertise Andy. Not so many of us here still fixing old bikes now.
I am doing a bit of work on the T120r but just about 1 hour a day then sometimes, like Today, no work. Monday should see progress

Re: The KH 400 Gearbox

Posted by Andy C <iframe src='https://members5.boardhost.com/classicbikemart/info/user=Andy+C' width='330' height='300' border=0 style='border:none;'> on November 18, 2024, 6:18 am, in reply to "Re: The KH 400 Gearbox"

Thanks Jerry - I am taking my time over this as I have no plans of ever doing another complete engine strip / rebuild on a bike after this one.

That being the plan I want to take my time to put everything back together as it should be.

This build I shall probably put the expansion chambers back on it and spend some time getting the carburation right, did not manage to nail it last time - sounds bloody lovely with the chambers.

Only thing is with all the time and expense I shall probably want to keep it for a while rather than let someone else have the benefit of my hard work, also prices seem to have dropped as well

Who needs a signature anyway......

Re: The KH 400 Gearbox

I'm like you Andy but decided to stop big strip downs and rebuilds a while back. I now just stick to general servicing etc. Get to an age in life when time gets more precious so riding is more important. Lucky for me I have a one man business motorcycle mechanic 2 miles from me so can get anything done buy an expert at a fair price. Todays job for me is to remove the rear number plate bracket and headlight from my newly acquired CB350 and get them to the painters as they should both be black gloss and not the Candy Gold same as the bike.

The oldest rocker in town!

Jerry

Posted by geoff the bonnie <iframe src='https://members5.boardhost.com/classicbikemart/info/user=geoff+the+bonnie' width='330' height='300' border=0 style='border:none;'> on November 18, 2024, 9:59 pm, in reply to "Re: The KH 400 Gearbox"

Jerry, many CB 350s had colour coded headlights although some had black but all had black rear light brackets. I expect your headlight is correct for that bike and model year

Re: Jerry

Thank Geoff but too late it's at the sprayers. Easier to get black gloss done than try and match the Candy Gold and the headlamp had a couple of deep scratches that I wanted filled.

The oldest rocker in town!

Re: Jerry

Ok, no one will notice as there are so many either black or in the bike colour. My 360 had a chrome headlight shell and chrome guards when new. 1975 model year but it was a USA CL model. Worth a lot of money now and the current owner does about 50 mile a year. If you see SDV 43N at any shows, that was mine and a very nice looking bike.

Re: The KH 400 Gearbox

Posted by Leon Novello <iframe src='https://members5.boardhost.com/classicbikemart/info/user=Leon+Novello' width='330' height='300' border=0 style='border:none;'> on November 18, 2024, 6:12 am, in reply to "The KH 400 Gearbox"

When one tends to fall off one`s motorcycle, one tends to not feel like fixing the motorcycle.

Leon Novello

Re: The KH 400 Gearbox

Leon - the last time I fell off a bike without it being someone els's fault was when I had my Harley.

I was turning around in a narrow lane and I stalled it and down I went.

Apart from my pride the only damage was a broken brake lever.

Who needs a signature anyway......

Re: The KH 400 Gearbox

Posted by geoff the bonnie <iframe src='https://members5.boardhost.com/classicbikemart/info/user=geoff+the+bonnie' width='330' height='300' border=0 style='border:none;'> on November 18, 2024, 11:00 am, in reply to "Re: The KH 400 Gearbox"

Last time i fell off was 1979 when a car pulled out. That damage caused me 4 years off work and a lot of pain all my life and still having body repairs.
Good job his insurer gave me enough for a house and new car at the time.

Re: The KH 400 Gearbox

Posted by laverdabru <iframe src='https://members5.boardhost.com/classicbikemart/info/user=laverdabru' width='330' height='300' border=0 style='border:none;'> on November 18, 2024, 11:19 am, in reply to "Re: The KH 400 Gearbox"

I don't enjoy working on bikes now, just do basic servicing.
May have to do a top end overhaul on the Honda 125 soon, talk about coming full circle. Used to do them on the kitchen worktop in an afternoon - 45 years ago. Will try to DIY that.
Other jobs, luckily I have a local family small dealer nearby. Reasonable rates, as the current mechanic is the son of an old workmate, & I encouraged his interest in bikes when he was a kid.
I also know a retired mechanic who I go to for small jobs, tyre changes ect.
Funnily enough, he used to work for the above firm & they haven't got a good word to say about each other!

Re: The KH 400 Gearbox

Posted by Beezabryan <iframe src='https://members5.boardhost.com/classicbikemart/info/user=Beezabryan' width='330' height='300' border=0 style='border:none;'> on November 18, 2024, 8:39 pm, in reply to "Re: The KH 400 Gearbox"

BeezaBryan

He knows not where he's going, For the ocean will decide,
Its not the destination, It's the glory of the ride (Edward Monkton, Zen Dog)

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