pos. 2ND GEAR IS GOING TO KILL ME

Hoosier Tom · Post by **Hoosier Tom** » Mon Mar 31, 2014 12:33 pm

Before you start ordering parts I would recommend you get the cases split and inspect your trans for the hows and whys of your 2nd gear jumping. Look at the depth of your dog engagement, dog wear/damage, see what cotters you actually have in there now. You'll also need to look at your forks and shift drum.

HT

48lesco · Post by **48lesco** » Mon Mar 31, 2014 5:45 pm

That's all good advice, including the study and learn part in the previous post and...

HT - I didn't realize you had given the part numbers before - didn't mean to step on ya!

Hoosier Tom · Post by **Hoosier Tom** » Mon Mar 31, 2014 6:20 pm

Chuck,

My toes are just fine, that was a good post by you. We're just emphasizing a point and repetition leads to learning for those that want to know more about their machines.

Cheers- HT

SWARDLAW · Post by **SWARDLAW** » Mon Apr 14, 2014 11:12 am

Don't know if you,ve gotten this problem fixed but mine was doing the same thing. I tore mine down twice to check the condition of the gears and the dogs, both were fine. Turns out the shift fork just needed a little tweeking. When shifting into second gear it was not fully engaging the dogs. Takes a little bit of time to get it just right. Now it never kick out of gear. A pain in the butt to pull the motor again but it will be worth the effort. Good luck.

redblk63 · Post by **redblk63** » Thu Apr 17, 2014 1:47 pm

I just want to add a ditto to the advice so far.

I had the same type of symptom. In my case it was caused by a bit of rounded edges on the 2nd gear dogs. It doesn't take much. I would not be surprised to see a backup transmission have the same problem. My solution was to buy a good 2nd gear.

Oh yeah, be sure and consider Xing the gears if you go in there.
Pro: Reduces the big gap from 1st to 2nd, and makes 2nd and 3rd more usable around town. Evens out the splits between gears. Easier for me to ride as a result.
Con: Increases the 3rd to 4th gap which is bad for racers.

apophis · Post by **apophis** » Wed Apr 23, 2014 12:04 pm

I just got the .040 cotters. Had to special order them. I will compare the (2) second gears I have as well as the shift forks. The only reason I didnt suspect them off the bat was I changed them and the shifting issue changed 0.

I understand the argument of dont order parts until you get in there, but my time is limited to do the work so if I tear down, I prefer to rebuild while I am there if possible. I might not get back to it for weeks if I dont reverse the whole process while its on my mind.

which 2nd gear did you have the rounded dog ears? the mainshaft 2nd or the countershaft 2nd?

apophis · Post by **apophis** » Fri Apr 25, 2014 4:12 pm

i am not sure which 2nd gear component gets the primary dog wear. The Mainshaft 2nd or the Countershaft 2nd