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  • #1

    One sloppy shift...

    I missed a 1st-2nd shift a few weeks back, and after that it started jumping the 2nd gear dogs under load. I got a day off today so I've decided to do the "2nd gear fix" that TopCat posted the walk-through for.

    Anyway I started about 9am, so far I have the bike turned over, gearbox stripped and the "dremel work" done with my trusty die-grinder. One thing I noticed is that the 2nd gear dogs only contact by a tiny amount in the slots, like about 1/3 of what could be if they were pushed fully in. I'm considering turning some material off the hub of the 2nd gear and using a spacer behind the 2ng gear cog to jack it towards the sliding gear.

    Has anyone done this, and if so what results did you see? I don't want to be repeating this process again anytime soon.
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  • #2
    What about the shift fork? Wouldn't it also have to be modified to move the gear over that additional distance too?

    Steve
    80 XS1100G Standard - YammerHammer
    73 Yamaha DT3 - DirtyHairy
    62 Norton Atlas - AgileFragile (Dunstalled) waiting reassembly
    Norton Electra - future restore
    CZ 400 MX'er
    68 Ducati Scrambler
    RC Planes and Helis

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    • #3
      Not if you moved the non-sliding gear towards the sliding one. I abandoned the idea eventually, and just did the dremel trick. Seems to be working just fine now.

      Many thanks to TC and others for taking the time to put up the step-by-step instructions, it saved me hours of work.

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      • #4
        Dayam Pete,

        You're just too quick!! I was just going to post about a different aproach that GNEPIG found to this problem, and he promised at XS East to post his info about this, but here's a paraphrase!

        He found that like you said, the non moving gear has some slop on it on the shaft, and IF it were moved over it would engage the moving gear better! He made a spacer to go onto the END of the counter shaft that the gears ride on, and this shifted things over pushing the non-sliding gear in deeper into engagement with the moving gear. I think he also removed the spacer washer between 1st and 4th to allow more movement of 4th into 1st. I realize these are different gears than you 2nd/5th combo, but I think he said it contributed to better engagement of them as well? Did you inspect your 1st/4th dogs/slots while you had the gears out? They are square cut and 1st is solid, so they are tougher to dremmel and undercut, but can be done, and "could" have saved you a second trip inside the tranny, but you've got it all buttoned up already, so I hope 1st hold for you?!

        Glad you found the info helpful, that was mine and Ken's idea for this and all the other tech tips! Ride On!
        T.C.
        T. C. Gresham
        81SH "Godzilla" . . .1179cc super-rat.
        79SF "The Teacher" . . .basket case!
        History shows again and again,
        How nature points out the folly of men!

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        • #5
          All of the other gear dogs wer in good condition. The bike has only done 14k miles, so very little wear except that the shift fork that moves the sliding 5th gear was heavily worn on the gear side, which will probably be compounded by my undercutting the dogs. I'll cross that bridge when I get to it, I didn't have time to mess about with that as I'm off to work on the bike in an hour

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          • #6
            .. oops, i have droped the ball, sorry TC and Pete. i've been a little tired this week, i have the changes written down in my manual out in the garage. i will post my findings and measurements tomorrow
            Gene

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