1st,2nd,4th and 5th gear fix...

[the108penguins]

wait what happened to 3rd I suppose 3rd never has any problems so it doesn't get any attention

I've decided to go ahead with the removal of the gears and do the gear fix (sounds like all the gears need to be fixed... maybe just put in a different tranny on these bikes ) I'm following the instructions on how to do it in the repair board, and I've gotten to the part where the shift forks are out (well two of them at least) but the counter shaft doesn't want to move so what am I missing here?? I believe I've read everything and have done it correctly but I'll go back and read it again just to be sure. HELP!

[bikerphil]

Did you remove the bearing cap on the left side (3 torx bolts) and the 14MM bolt on the right side? Did you slip 5th gear out the left side thru the bearing cap hole? If you've done the above, tap the shaft from right to left where the 14MM bolt was and the countershaft should come free. Then wiggle it out.

[the108penguins]

up-grade

ok I got it, just had to tap out the shaft from the clutch end (very gently and with a short piece of wood broom handle) now my gears are sitting nicely arranged on a rag, ready for "upgrading"

[bikerphil]

Good deal. Good luck with your upgrading.

[the108penguins]

for those of you who are thinking of doing this fix yourselves but may not be sure of opening up the tranny I thought I'd detail what I've been running into to give you a heads up just in case you meet with similar challenges. I'll post pics and more details soon.

[DGXSER]

I've done this fix three or four times now. Everytime I do it, another step in the process becomes the hang up. Typically it is getting the gears and or shift forks back in that creates the most torture in my experience.

[CatatonicBug]

I've done this fix three or four times now. Everytime I do it, another step in the process becomes the hang up. Typically it is getting the gears and or shift forks back in that creates the most torture in my experience.

I agree completely! Getting everything to line up is the hardest part. I tried using a long screwdriver as a "fake" shift fork shaft, but found that a piece of solid 14 gauge wire (one piece from inside a section of Romex) allows for more adjustment and makes it even easier.

[the108penguins]

ok so here are my gears before grinding them for your inspection and critique. they don't look like they've had much use and aren't rounded much but I'm doing the fix anyway. It seems like pretty much everyone has had this problem so I'm not waiting till I hear grinding noises. removing the gears wasn't too much of a problem only a few parts have to come off (the gear shaft bearing on the shifter side and the bolt/washer on the clutch side) and the gear shaft will slide to the left of the case and then drop down (hey it's just like they said it would) on mine I had to gently tap the end of the clutch side shaft with a thick dowel to get it out of the bearing because it's a really close fit. I removed the two outside shift forks before I dropped the gears but I've heard that you don't have to take them out at all... not sure how that would go but it would be nice if it worked.

http://www.kodakgallery.com/imaging-...890212/jpeg/BG

http://www.kodakgallery.com/imaging-...890212/jpeg/BG

http://www.kodakgallery.com/imaging-...890212/jpeg/BG

http://www.kodakgallery.com/imaging-...890212/jpeg/BG

http://www.kodakgallery.com/imaging-...890212/jpeg/BG

[bikerphil]

Those links don't work over on this end.

[the108penguins]

ok try these

[CatatonicBug]

Wow! Very nice and clean! The first two look almost brand new. If they were mine, I'd just put them back in the way they are. The last two show a little wear, but still not much. Definitely a nice, easy one.

[the108penguins]

ok so here's what they look like after I ground the dogs and slots I'm not sure if I got pics of all the gears.

















it's a bit tough getting the dogs and slots to match up nicely by hand

[bikerphil]

Can you make them pics any smaller, lol? As long as the rounded edges are gone and the dogs and slots mate equally, you should be fine.

[the108penguins]

yea the rounded edges are gone but I'm not sure how closely the dogs match up to the gear with the short ledges because I can't see in there... where's X-ray vision when you need it. how much variation will these tolerate?

[motoman]

Unless you ground them blind-folded.....should work fine! See a little gaulding where the fork rides, but will be fine. Some of those early pics gave suspect to oil either being extremely low, Never chaged or both. Those new pics verify that! Betin' that scoot was used and abused. Should still give you many a mile and a smile though....best part, is YOU fixed and earned the lasting smile!