1967 CB77 Transmission Issue

[DianneB]

I recommend you check the actual location of EVERY gear.
I think you have gears in the wrong location. ................lm

LM is right on the money! I can assure you that SOMETHING is wrong - that gear noise is ONLY made by gears that are engaging too deeply so either one of the shafts is in the wrong position or one of the gears is.

Did this transmission ever work properly?

If it did, what work has been done since then?

Go through it again - take it apart and reassemble by the parts list http://www.cmsnl.com/honda-cb77-super-h ... E++07.html

[mike in idaho]

Try turning the shafts with the kick-start shaft held clockwise against the stop to retract the pawl.

[malcolmgb]

Make sure you have the kickstart pawl the correct way around, it can be assembled wrong.
........... don't ask me how I know!

[zads]

Hi Guys,

Thanks for the replies.

One thing I should of noted is the kickstart prawl is not in the transmission right now. I did have the kickstart prawl in the transmission, but when this issue came up I have been taking it apart and reassembling it to try and figure out why it is not turning smoothly and have not been putting the kickstart prawl in. Unfortunately that noise in the video is not the kickstart prawl, its just the transmissions gears.

G-Man, when I get home I will check the selector fork, I did replace one selector fork because one was visible beaten up. I'll rotate the selector fork to different gears to see if the problem exists in every gear.

DianneB, how can I tell if the shaft is in the wrong position, look for a damaged part? The transmission was really beaten up, I've had to replace the bushing on the end of the kickstart prawl that looks like a top hat (see attached picture), the kickstart spindle, the 14mm brass bushing, one of the fork selectors, the top gear and I eventually found the kickstart prawl and spring by the oil trap.

Mike in idaho, I'll try that when I get home.

[DianneB]

Try turning the input shaft in each gear position (https://www.youtube.com/watch?v=qjqhy7q ... =95.403812) that might give you a hint what is wrong.

It is obvious that the counter shaft and input/output shaft are too close together which causes the gears to bottom out and the shafts to 'jump' on each gear tooth.

It isn't a bent shaft or it would be noisy for half a rotation and quiet for the other half.

The hard question is WHAT has changed and why and that is impossible to determine from the pictures. Are any of the bearings new?

[G-Man]

Interesting! When you're turning the shaft, try resting a finger on each gear in turn to feel where the vibration is coming from. I cannot see any interference on the dogs that would cause that noise.

Could you have mixed Dream and CB gears? Dream gears have no undercut on the dogs so should be obvious and will have different tooth numbers......

You say you have counted all the gear teeth. Let us know what those numbers are, just in case.

G

[Tim Miller]

You might have some mix match early and late gears (000 vs. 010) they have different machining depth on teeth. Remove one gear (2nd or 3rd)at time a try again.
Been there done that. I have a NOS 3rd gear 23460-258-010 with large fat teeth that if mated with 23451-268-000 would do exactly what yours is.

Tim