2nd gear questions

[onefour]

So I've been in, and did a minor back cut on my 2nd gear dogs... Lasted about 2 rides with the extra power...

Looks like my second gear is meshing only about 1-2 mm? Whats with that?

When I was in the first time it looked pretty untouched... rounded bit on the dog teeth was maybe 2.5mm down from the top of the gear.... if that.

Anybody tried welding more material on the tops of the dog teeth?

This is the only way I can think of doing this fix easily, as moving the washer/cutting a groove in the gear involves shift fork work as well...

Anybody have any info or links etc on this type of situation/fix????

Anybody know the type of steel the gears are made of? The gear would probably need a re-temper after the weld...


Thanks.

[DGXSER]

lot of the folks on here move the washer. No shift fork work is required. It basically doubles the contact area of the dogs and gear. I also would suspect you went a little to easy on the grinding and did not get a good unrounded edge on the dogs. But really the washer swap is the best bet IMHO.

[onefour]

That washer is a thrust washer and really should stay there no?

[madmax-im]

That washer is a thrust washer and really should stay there no?

no it can be moved ...I've done this as well as many others have....in my case on my XJ1100 i had the $ to just buy all new factory backcut gears...never will have that problem again...it does sound like you didnt dremel the gears enough as was mentioned above...its a fix that should last alot longer than 2 rides...

[bikerphil]

Many of us just move the washer to the other side of second gear, letting the clip ride against the gear with no problems. Others, not very many though, have machined the thickness of the washer off the side of the gear and added a second washer along with moving the original washer. Either way it is a 100% improvement with the dogs engaging deeper in the slots.

[onefour]

no it can be moved ...I've done this as well as many others have....in my case on my XJ1100 i had the $ to just buy all new factory backcut gears...never will have that problem again...it does sound like you didnt dremel the gears enough as was mentioned above...its a fix that should last alot longer than 2 rides...

Haha one would think right? I can assure you they were nice and pointy and back cut with idk like a 3* angle?

Many of us just move the washer to the other side of second gear, letting the clip ride against the gear with no problems. Others, not very many though, have machined the thickness of the washer off the side of the gear and added a second washer along with moving the original washer. Either way it is a 100% improvement with the dogs engaging deeper in the slots.

I do have a mini lathe, although not a great one, how hard are the gears? I thought of this and thats why I thought it may be better to add material to keep all factory thrust washers in their correct places? And the shift fork as well?

[DGXSER]

I can tell you I have over 7k miles on mine with the washer swap and no added second washer etc, no ill effects yet.

[crazy steve]

...Anybody know the type of steel the gears are made of? The gear would probably need a re-temper after the weld...

I'm reasonably sure the trans gears are cast iron, then surface hardened. Once you grind through the surface hardening, the metal is pretty soft. I wouldn't recommend welding on them.

And you did back-cut grind the receiving slots for the dogs, right? Failure to do that will prevent the dogs from staying engaged, even if reground.

[onefour]

And you did back-cut grind the receiving slots for the dogs, right?

Yessir

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