Stiff Gear Change
 

After replacing my chain I've found up shifts are really stiff.

I'm sure the chain is adjusted correctly, but can't figure out why its done this. The only other thing I did was to tighten the bolt that holds the gear change rod at the engine side as there was a lot of free play in it. Slackened this off again and it still is really stiff, to the point of having to change up MX style. Down shifts are fine and the clutch is working (little heavy but that's due to me not setting it back up correctly) correctly.

Suggestions please?

There are two little ball joints at the end of the long rod that goes from your peg area to the gear shaft. The two flat edges on the ball joints (peel back the rubber covers on both of them) should be at the same angle. I know if they aren't, then it can be hard to find neutral but perhaps it is something you could check.

Getting into neutral isn't a problem only seams to be while moving (but then you don't really go up and down the box stopped). But will defiantly take a look at the joint.

If it was ok before the new chain and now doing this I'd say it was something you disturbed ... obvious suspect is the worm gear thingy. Did you so the sprockets too?? if so you would have had to remove this?!

Sprockets were done at the same time. Disconnected the clutch cable didn't have to remove the worm, that should be okay as I only swapped it over from my spare engine the other week after the original snapped.

But as soon as I get in (and dry) I will take the sprocket cover off and give it a once over.

There is actually a reasonable amount of play in the bolt holes on the worm-gear mounting bracket ... so it is hard to get it put back on exactly as you took it off. So unfortunately you will still need to readjust the cable (to get correct angle of the dangle) and the worm-gear adjusters to make sure everything is setup properly.

It might be something else, but setting it up properly isn't going to do you any harm or cost you anything ;)

On the way back from work it seamed to loosen up a bit.

Got it up on the paddock stand and checked the worm, altered the clutch cable as I hadn't set it up properly (getting the adjustment, just right), then tightened the chain as it had became a little slack after bedding in.

With it on the stand I fired it up and took it up and down the box... and all seamed fine. Will be out on it tomorrow but what ever it is seams to have sorted itself out, strange?

Lube the pivot where the gear lever fits around the footrest.These seize up and cause the problem you describe.