Dremel Fix

[CatatonicBug]

You can reuse the oil pump o-ring. If you have one though, feel free to replace it. As for the 3rd gear dogs and slots, I suggest grinding those too. I learned that lesson myself and had to go in a second time. Replace ALL the gaskets with yamabond or similar rtv. Do not reuse gaskets. The yamabond will actually be a better seal than traditional gaskets anyway.

[jetmechmarty]

Always use a new packing (o' ring) if you can. I don't believe you need to mess with 3rd gear. I didn't.

[TopCatGr58]

Hey Bill,

Sounds like you may have been PO'd, the screws are supposed to be torx, but if not, then "somebody" switched them for phillips heads! Probably still had lock tite on them so that's why there were so hard to get out. Would suggest you replace with new but your choice, torx or philips, just don't forget the locktite again.

The 3d gear dogs/slots were found to be undercut already on my 81SH, some/few folks have reported the skipping problem with 3rd, but is rare, but if yours show signs of rounding off, then by all means grind away!

Glad the photos were helpful, that's why I put them in there for folks. Ken Talbot had done a great job with his previous tip, but the manual photos seemed a bit lacking.

Others will recommend doing the washer swap, you can search for info about that and decide for yourself if you think it will be necessary to help prevent or reduce the chance of this recurring, but IMHO if you get the dogs/slots angled just a bit more, they will hold and holdup just fine. YMMV!

T.C.

[BillyRok]

I was just reading about the washer swap. Factory set up has a circlip between 2nd and 5th gears with the washer between that circlip and 2nd gear right? The swap is simply moving the washer to the back side of 2nd gear so 2nd and 5th fit tighter together? Would this in any way put more stress on the circlip since the under cut gears will want to pull together anyway? I want to make sure I set this up right while I'm in there. Not that this hasn't been a fun ride but I'd rather not have to do it again.

[CatatonicBug]

Would this in any way put more stress on the circlip since the under cut gears will want to pull together anyway?

That's the argument against doing the swap. I understand the concern, but I don't think anyone who has done the swap has seen any symptoms related to that problem. I have done the swap myself on all but one of the trans. that I have fixed (the countershaft just wouldn't go back in on one of them with the washer swap done), and never seen an issue with that circlip. Your choice, but I recommend it.

[TomB]

I recommend it.

+1.

I did the washer swap and 2nd and 4th gear grind, while you're in there it seemed daft not to.

Worries about the circlip I understand but you must remember that any sideways forces are pushing away from the circlip, thats why 2 gear was slipping out.

[DGXSER]

First, yes, the swap is simply taking off that circlip, removing the washer between it and the gear, remove the gear, put the washer on first, then the gear after grinding the slots, and then replace the circlip.

The debate has been gone over a few times as to the wear on the circlip with the swap. Some are concerned the corner on the circlip may wear, others that the ends will wear into the gear. My opinion is that the washer was a spacer only. And use seems to prove it was not needed or should have been on the other side. I have moved it on all the bikes I have done this repair on.