2nd gear issue came back

[Wouldstalk]

about 6k miles ago I did the dremel fix on my 2nd gear and what i think are the dogs on 5th gear, as well as moved the washer over.

Now second gear is nearly completely unusable again.

I want to just go ahead and buy new gears so that this wont happen again. Do i need to buy both 2nd and 5th gear to fix this problem? Anyone know a good cheap site to buy both? Some sites have them for almost $200 if they have them at all.

Any help would be appreciated.

[DiverRay]

If you can get them, buy them BOTH NOW! They are getting VERY SCARCE now. That and a shift fork should take care of the problem.

[Radioguylogs]

Wouldstalk:

Yes, dogs are on 5th gear, engage into slots in 2nd gear.

You can get 2nd gear from the dealer, but not 5th gear.

Once in a long while, a 5th gear shows up on e-Bay. I was lucky enough to find one when I needed it this winter.

Andreas had two decent transmissions available over the holidays. Don't know the current status.

I hope you show us pictures when you get it apart so we can learn why yours didn't last very long.

[mack]

What

was the cause of the second failure. This maybe very informative to our members!

[James England]

I last saw new gears on www.cmsnl.com

[jwhughes3]

If you have to grind the thin, hardened layer off the dogs, it only buys you time enough to find replacement 2nd gear. The softer dogs will wear exponentially faster.

John

[Nightengale]

Gears

When I did my gears (with T.C) I found a whole set of tranny gears on eBay and got the whole thing for $25. Just had to look for a while to find it.

[clcorbin]

So has anyone tried welding up the rounded over dogs and then grinding them back to the original position? One of the problems with welding is it is usually much harder than the base metal, so that should actually help in this situation.

[motoman]

So has anyone tried welding up the rounded over dogs and then grinding them back to the original position? One of the problems with welding is it is usually much harder than the base metal, so that should actually help in this situation.

.....you'd think, but unfortunately the heat draws added carbon out of base metal, in this case the part you prefer to stay in place. Broken off engagement dogs would not be a good day.

[Fearthepack]

I live in Orlando FL and plan on taking mine to a local shop who gets all gears reverse cut for $250. I plan on before and after pics. The owner of the shop is awesome and says the work makes them better then new. Maybe I can get a direct connection to the guy that he uses.

[Tenorman]

Some gears are available...but you'll have to really search!

When I did my bike last year, I searched for new gears from Partzilla.

The 1st Gear was still available, but they showed that the 4th Gear was, but later emailed me that it wasn't. I bought the 1st gear (about $100.00 with shipping).

I found another 2 NOS gears on eBay...4th and 2nd...bought them...about $100.00 each. I then bought a good used transmission on eBay...another $100.00.

You'll look long and hard to find the 5th gear although they do come up on eBay once in a while...maybe $100.00 if you're lucky.

I ended up using the 5th gear from the used transmission along with the 2nd gear washer. (I had the new second gear cut so I could use 2 washers...one on either side.)

If I had to do it all over again, I would have contacted these people

http://www.fastbygast.com/Catagories...nsmissions.htm

The FJ owners site has a ton of information on these transmissions, because they also had problems with the 2nd gear on the early FJ1100 and FJ1200.

I'm looking for a good used FJ1200 for a new project and it appears that the 2nd gear problems were less apparent on the 1989 and later models of the FJ1200.

By the way...I never found a NOS gear that was undercut...I don't think that they ever existed. All that I found was NOS...NEW OLD STOCK...

Hope this helps....

Tenorman

[Tenorman]

Here's a photo of the bike....

I took this photo a couple of weeks ago...a labor of love and it always cries out for something else. But the transmission works great and it screams...

After looking at this photo, I noticed how bad the center stand looks, so that will need to be removed, sandblasted and painted...if Spring ever comes to Western Pennsylvania...but that will be after I clean-out the garage...

[/URL]

[Radioguylogs]

If I had to do it all over again, I would have contacted these people

http://www.fastbygast.com/Catagories...nsmissions.htm

Tenorman

This sounds like a great solution over Dremel-by-hand. I can't wait for someone to try it and provide a report with pictures.

[motoman]

This sounds like a great solution over Dremel-by-hand. I can't wait for someone to try it and provide a report with pictures.

Considering the make-up and tolerances internally with these trannys , unless your doing a track bike, IMO, save the money for other needed 'fixes.

[thumperjsa]

There is a 5th on ebay now.
http://www.ebay.com/itm/Yamaha-NOS-G...3a2d79&vxp=mtr