dremel/ black and decker fix

[glenn]

Hi
i know this has been done by many but I am not sure to what accuracy the grinding/finishing of the job has to be. Is the use of plasti gauge or engineers blue necessary. Your thoughts would be appreciated.
thanks in advance
Glenn

[glenn]

dremel black and decker fix

Hi again
i should have asked this in my first lot. Does anyone know the minimum useable width on the shift forks measured across face to face. How do you tell if it is bent other than it is obviously way out of whack. last but not least the pin??? on the back should measure out at what height and width across the face. i am guessing that a combination of all these would give a fairly high margin for errant operation.
glenn

[TopCatGr58]

Hey there Glenn,

Well, I can only tell you about my experience, having done 3 of these, 1 XS and 2 XJ's, both 2nd/5th and 1st/4th combos. The tolerance is fairly forgiving. I used a micrometer in mm scale to 'try' to get the width of the 3 dogs as close as possible. I also dremmeled the slots on the receiving gears, but didn't do any measuring there, just eyeballed the surface. These tranny's are pretty tough, even though the dogs like to wear out!!

Can't help you much with the shift fork, aside from the fact that I put all three OEM's back in the bikes, and they shifted and held their gears, which was due more to the effective backcutting of the dogs/slots to mimic a slight dovetail type joint!!
HTH, T.C.

[glenn]

dremel/b&d fix

Hi Topcat
thanks for your reply. What you have written sort of confirms my thoughts. When looking at some of the cog faces there only appears to be a 3mm contact zone
between the engaging gears. i would asume that minor differences would "even" themselves out quickly with usage
My reason for the questions about the other parts was I figured that too much slop on the other parts would not allow for as positive a shift and may cause the initial gear mesh to be incomplete.
guess I should get out more often
Regards Glenn