Second gear slip

[DiverRay]

Be advised, sometimes the gears will not quite fit when you do this. I ran into this on Special Ed's bike. We couldn't fit the shaft back in, so we had to "undo" the swap. He still was able to ride like a madman, but then he ALWAYS rides that way.

[DGXSER]

You will want to look in the tech tips under the "Dremel Repair" guide for fixing 1st or 2nd gear. Click HERE

Follow the procedure, however, you may want to ignore the Dremel work and only swap the washer.

[motoman]

Be advised, sometimes the gears will not quite fit when you do this. I ran into this on Special Ed's bike. We couldn't fit the shaft back in, so we had to "undo" the swap. He still was able to ride like a madman, but then he ALWAYS rides that way.

Very true........plus mine had FULL engagement(dog flush with backside of slot) when in gear, so no washer swap, just dove-tail 'dogs' and matching back-cuts of load side of slots. That was six years ago and 30+k miles. I can tell you with the slot ends angle ground to match dovetail on dogs, every so often a slight throttle blip is needed when downshifting to release the 'fit'.

[TopCatGr58]

Hey Motoman,

I'm glad to see another experienced rider/mech that has done the dremmel and did NOT do the washer swap. I haven't done the swap either, just did a decent undercut angle, and mine have also held, although I think I've only put on about 15k miles, but I have ridden it fairly strongly, the occasional wheelie, and very strong accel runs, plus lots of running in the twisties in 2nd and 3 gears with strong decels also....nary a glitch or skip!

Still say, if you're going to go in that deep to swap the washer, it would be foolish IMHO to not perform the dremmel touch up while there! And to do ALL 4 gear sets, 1-4 and 2-5...and another member will say even 3rd...his went out also....so essentially all of the gears are susceptible to the failure, and I would say the lower gears moreso due to the more frequent transition thru them. YMMV!

T.C.

[motoman]

Hey Motoman,

I'm glad to see another experienced rider/mech that has done the dremmel and did NOT do the washer swap. I haven't done the swap either, just did a decent undercut angle, and mine have also held, although I think I've only put on about 15k miles, but I have ridden it fairly strongly, the occasional wheelie, and very strong accel runs, plus lots of running in the twisties in 2nd and 3 gears with strong decels also....nary a glitch or skip!

Still say, if you're going to go in that deep to swap the washer, it would be foolish IMHO to not perform the dremmel touch up while there! And to do ALL 4 gear sets, 1-4 and 2-5...and another member will say even 3rd...his went out also....so essentially all of the gears are susceptible to the failure, and I would say the lower gears moreso due to the more frequent transition thru them. YMMV!

T.C.

Well T.C., Way back when, I was one of those that dissagreed with the washer swap anyways. And yes, I did them all, even the 'bottom' slots and their mating 'dogs'. Never said much about it as I kinda got 'slammed' here even after explaining the reasons 'why not'. I initially, after done took it out to the local 'strip' here and pounded it fairly hard with clutch speed shifts and only noticable issue was a bit of clutch slippage part way thru third by the third run. Being a 'tree' person with cages over the years, it was a bit different on the scoot, but in full dress form here at 5000ft., scoot still turned respecable high 13's low 14's without 'cowboying' it too hard off the tree trying to get low 60ft. times.