Stripped Club - First Gear

[buickyouth]

So, I know theres a lot of talk and documentation of the second gear fix.
But how about replacing the first gear? On a level of 1-****! how big of an ish is this? Below is the diagnosis.

Seller told me that the guys he got it from rode it 'hard'
All other gears seem fine.
1st will hold under 2k RPMs but slips out with a chunky clunking above it.
Clutch just reassembled to manual specs.
Clutch cable replaced.
Clutch adjusted properly.

I feel comfortable riding it around as is (as I've learned how to work with what I have). Still the guy I'm selling this bike to might want to do something about it. What's the score here guys? Please advise.

[Silent]

You can follow the recent rebuild I just did on my XS tranny over on the FJR forum. Clickie It's worth at least scrolling thru and looking at the pictures anyway That will give you an idea of the dificulty level. I had no help other than the manuals and this board to guide me.

[buickyouth]

Thanks, I just scrolled through TopCat's repair thread for the 1st and 2nd gear fix too.

[DGXSER]

I just finished the gear repair on a members bike. With two of us, we just spent three and a half hours.

He had a spare engine with good gears, so he removed the countershaft last night from the spare and tonight we removed the gears from the runner on the centerstand, did the washer swap to second gear, put eveything back together minus the three covers/pans being reintalled. I had completed the repair on my bike over the winter, so I was already familiar with the process. Having two people definitely made it go much faster.

[Bigfoot]

I have done this a couple times myself as well. Same process as the second gear. Seems to take about 3-4 hours with two people. The last time I used a cut-off wheel on a die grinder to grind the dogs and a stone on the slots. The cut-off wheel made the job alot easier.

[CatatonicBug]

Definitely not a super difficult thing to do, and I learned a TON about my bike in the process. I too used a die grinder for the majority of the grinding, but since I didn't have a cut-off wheel for mine, I switched to a dremel for the finishing work. You could always replace the gears too, if you had them, but its a lot cheaper to repair what's there.

[bikerphil]

Another option is new back cut gears, about $100 apiece.