Seized gearbox?

I've just changed the clutch on my 99 SV650s, and refilled correctly with fluids. I can't now get it to go into gear. Engine runs smooth, just when you tap the lever into gear, it shunts forward 12 inches and stalls. HELP!

Full timeline of bike.

Purchased 2 weeks ago.
Road about few days, occasional missfire.
Coming back from a night at a friends, big bang and coasted to a halt. Missfires etc and can't get to start.
Get her home, look on forum, seems may be getting water onto front spark, so fix problem with the grease jobby and an extenda for da fenda.
While i'm at it, discover a small hole in the rad, so get this putty'd up.
Upon restart, didn't really want to play games and seemed to have little clutch bite. Thought i might have seized the clutch, and so...
Order clutch.
Clutch removal and replace - a la haynes
Start-up, loud clunk, but seems to work ok.
Take around the block. Stops. Nothing. Engine ok, but nothing in the box.
Get home, open up side of box, and see broken oil pump gear.
order and replace oil pump gear.
All is fine on start up. Go to change gear.

NOTHING FROM BOX. Engine ok, so i'm pretty lost as to what to do.
Any advice?

[maviczap]

Have you checked the clutch cable for free play?

Is the worm gear behind the sprocket cover working properly?

Couple of basic things to check first I think?

all seems to be. when the side of the clutch was still open i checked the movement, and there was plenty there to dis-engage the clutch. I just can't understand why is does it when you pop it in, even before clutch release.

and i can free wheel it about with the engine off and in gear, so long as i have the clutch in. I'm so very lost....

Failing all this, how long do you think in terms of time, would it take to strip and rebuild it? I'm fairly experienced and have all the tools at my disposal, just not done it on a twin before.

J

[maviczap]

Originally Posted by jimathyy

Failing all this, how long do you think in terms of time, would it take to strip and rebuild it? I'm fairly experienced and have all the tools at my disposal, just not done it on a twin before.
J

Pass, I'd have to take mine to a garage

based on the symptoms i would say the clutch is not disengaging when the engine is running. I would firstly look at the work you have done.
What was the condition of the old clutch? you seem to be spending good after bad on this and i would look at investing the cash else where.

[Biker Biggles]

"Broken oil pump gear"
That would ring a few alarm bells for me.

I had same problem after fitting new clutch plates not on an SV turned out to be the last plate that should have been fitted was thicker than the rest. If you fitted one of the thin plates it jumped out the clutch basket locking the clutch. might be worth pulling clutch plates out to check differance in thickness is noticable by eye when you know what your looking for. hope that might help.