Last fall due to all the problems I was having, I swapped out the entire transmission setup from a donor CL77. I swapped out the full tranny, shift forks, shift drum.
No change.
I rebuilt my 6 plate clutch. new disks
No change.
I got a 5 disk clutch, rebulit, from ebay.
No change
I got a 2nd 5 disk clutch from ebay.
No change
replaced all inner case shifting parts with NEW NOS parts. New drum tensioner. new fork to move the shift drum. new spring.
No change.
I am at a loss. I am fine in 1st, 3rd and 4th. I shift into 2nd and here are the random things that occur.
1. take off in 1st. shift to second. everything is fine for several seconds, then it acts like I pulled the clutch in for 1/2 second at a random rpm and popped the clutch at a higher rpm
2. ride in 4th. coming to a stop in traffic. down to 3rd. all ok. down to 2nd all ok, wait the light turned green. accelerate in 2nd. wham. clutch disengages for a second, then slams reingages. WTF. All 3 clutch setups do this.
3. This one is my favorite. round a long corner in 2nd or accelerate from a stop and take a 90* turn in second. all is fine, then, no clutch a second, then slam reingages. this has almost killed me.
so donwshifting to second is fine as long as you dont ADD throttle. then something happens
I am at a loss. I have spoken and showed the bike to several people in CO with 305's. No one has a clue what is wrong. It does this at random, but only in 2nd gear
2 different transmissions. 3 different clutches.
pos. 2ND GEAR IS GOING TO KILL ME
Sounds like jumping out of 2nd gear, a trans issue, not a clutch issue. If you lose dog engagement in 2nd you basically have a neutral condition where gears are free spinning and nothing is giving power to the drive sprocket, which gives the appearance of clutch disengagement. Check the following for trans power flow
http://www.honda305.com/forums/viewtopi ... ansmission Did you read Bill's write up in his resto manuals on 2nd gear problems and the use of offset cotters? Factor in worn shift drum, bent or worn shift forks with std cotters and you may have what you are experiencing HT
Last edited by Hoosier Tom on Tue Apr 01, 2014 8:37 pm, edited 1 time in total.
i could understand if it was a bad 2nd gear or shift fork in my original transmission, but I replaced the original with a CL77 donor tranny, shift drum & shift forks to have 0 change in what was occurring. the donor shift forks looked great, very little wear and the tranny had perfect teeth on all gear.
I feel like it is low probability to get donor parts with the exact same problem. same gear. same exact symptom with no change At this point I'd look at things you haven't changed. Have you used the same clutch springs each time? They might be weak, and i believe there was one set (there were 3 different sets used ) that was prone to slipping. What type of oil are you using? Some have additives that aren't compatible with wet clutches.
63 CA78
That's great the donor trans had perfect teeth but the more pressing question is what shape were the dogs in and did you verify dog engagement by rotating the drum through the positions and check how much engagement you had? Did you use std or oversize cotters on main shaft 2nd gear? But a probability none the less. HT
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