2nd Gear

[Dad2g5]

I read the articles on the notorius 2nd gear problem. I removed the oil pan looked at the second gear slots and the pegs that go in yes they are worn (beveled at 45 Degrees). But I cant see that being the reason it doesnt grab. It sounds much worse when riding. I also found a snap ring and washer in the pan when I removed it. Cant figure out where it goes. Any comments? Thanks for your help.

[Dad2g5]

Another comment when I say beveled its only a tiny bit in the corner of the peg and slot.

[trbig]

The snap ring and washer is probably from the shaft that your oil pump gear is on underneath the clutch basket under the clutch cover. The gear can't go anywhere because the basket is so close to it, but the clip and washer do need to be put back on.

As far as the gears, they don't engage very far. That's why they are notorious for going bad, and why people move the washer to the other side of 2nd to make them engage slightly more. Even though the gears don't LOOK that bad, that's enough to make them skip.


Tod

[Dad2g5]

Thanks alot. Now I know what to do.

[TopCatGr58]

Another possibility!?

Hey Dad,

Another location for loosing the snap ring/washer is from the end of the shift fork shaft=the other end of the oil pump idler gear assembly, after it protrudes thru the left engine case side, where the SHIFT PAWL attaches to it. That chamber has a nice hole in the bottom to return oil into the crankcase, and so those parts can easily fall in there. The shift pawl will still be on the shaft because the gear shift lever case cover will keep it mostly in place, but it can be loose. And it may not be grabbing the shift drum properly to rotate it to allow proper shifting either.

You can see some nice pictures of this in the tech tips repairs shift lever return spring pictorial. Scroll down from the MAIN FORUM PAGE, not the link in the left yellow column to find it!

I would check there first before pulling the clutch housing cover off!

But it doesn't take much wear on the end of the dogs/slots to cause the gears to slide apart, since they are square cut!!
T.C.

[Dad2g5]

Thanks good idea. I thought so too I removed the cover before I posted today. I was hoping that was it. But no I'm not that lucky.

Thanks for your input though. Its greatly appreciated!