Grinding at 2nd gear

[vint1100s]

Bike shifts to 1st fine but won't shift to 2nd while running. All gears work fine on the bench when not running. I have already pulled the gear assy. and am prepared to do the dremel fix but I am still unshure that I am addressing the problem. I found a 1/8 dia. pin in the bottom pan and have not found where it came from. It didn't come from the shift fork drum but it looks like the same size pin.
Any Ideas?

[BA80]

Won't shift or won't stay in gear?

[motoman]

Oh...but it DID come from the drum.......better look again!

[DGXSER]

Yep, I would be suprised if ti did not. I would go ahead and perform the dremel grind ont he gears while you have them out, becuase they would eventually need it anyway. But that pin came from soemwhere, and with the shifting issue you described, the shift drum is about a 95%.

[James England]

Probably a broken star washer thingy. The gearchange is the onlyplace in the entire engine that has those pins. It's a 100% certainty....

[BA80]

Ahhh..yes. That's what it is. Here is a pic...



The arrows point to what that pin probably is. This is a picture of the shifting ratchet assembly under the left rear engine/trans cover. No need to tear into the transmission to take care of this problem. It can be done quite easily on with the bike up on the center stand.

These pics are from an old post by trbig authored with instructions on how to do it. Do a search and you'll find it. I'll look when I get a chance.

Here is a picture of the whole assembly.

[James England]

Usually one of the pin retaining lugs snaps off, allowing a pin to fall out, so I'd look for the broken bit and get it out of the engine. The star washer thingies are still available......

[CatatonicBug]

That pin may also be from the other end of the shift fork shaft. There is a retaining pin behind the oil pump idle gear (behind the clutch) that keeps the shaft from pulling out the left side and grinding that gear against the engine case.

[motoman]

That's NOT a pin Bug. That one is a roll pin....totally different and different use. You seriously need to have torn one of these down before giving info!

[CatatonicBug]

That's NOT a pin Bug. That one is a roll pin....totally different and different use. You seriously need to have torn one of these down before giving info!

Um... I've probably been into more of these transmissions than you, my friend. I am VERY familiar with the internals of that part of these bikes. A roll PIN is still a PIN. I was simply giving options.

[bikerphil]

Bike shifts to 1st fine but won't shift to 2nd while running. All gears work fine on the bench when not running. I have already pulled the gear assy. and am prepared to do the dremel fix but I am still unshure that I am addressing the problem. I found a 1/8 dia. pin in the bottom pan and have not found where it came from. It didn't come from the shift fork drum but it looks like the same size pin.
Any Ideas?

The pin may have fallen out of your shift drum and was replaced with a new one, never retreiving the original one from the oil pan. JAT

[motoman]

The pin may have fallen out of your shift drum and was replaced with a new one, never retreiving the original one from the oil pan. JAT /////+1, a good option!...... and the only other if a solid pin.

[vint1100s]

Won't shift or won't stay in gear?

Won't shift into 2nd.
Thanks

[BA80]

It has probably dropped a pin out of the shift drum then.

That's the pics I posted.

It won't go to 3rd or beyond when running either right?

An SF i am currently working on had that problem also. Pic isn't too good but this is what it looked like when I pulled the left rear cover.



See the tab broken from on star plate and the empty hole where the pin should be?

[3Phase]

vint1100s, the shift pawl body might be bent. I didn't even try to fix it, I just got another one that wasn't bent so it didn't do that.

It's not a major emergency or anything but if you don't fix it the tab will keep breaking off the washer and the 5th gear pin will keep falling out of the shift drum. It gets annoying. My '80G kept snapping that same 'leg' off the starfish washer and after the third time I put the bike over on its right side so I wouldn't have to drain the oil, then removed the cover for the shift assembly and looked at it while shifting the gears.

I found that when you shift up to 4th or 5th gear, the edge of the shift pawl body snags on the washer tab covering the 5th gear shift pin in the shift drum. Eventually it bends the tab up and breaks it off, then the 5th gear shift pin falls out of the shift drum.

I posted some pictures to a thread somewhere ... (Jeopardy music)

Ah, here it is and a link; better than a text description. If you look at the picture you can see that the edge of the shift pawl body next to the shift index pin and the shift pawl has a small flat spot worn into it from hitting the washer and the 5th gear shift pin:-

Why the shift drum starfish washer breaks