Why...... on dremel fix?

[Fearthepack]

I ask this after i did the fix.

[motoman]

What your missing is contact load needs to spread across the whole face of dog ear. The gear pictured needs excessive material removal to accomplish that, and if re-used after correcting, full throttle speed-shifts would be its demise in short order.
BTW, never seen dog-ears in that sorry of condition....they are badly 'hammered'.

[Fearthepack]

But... contact on 2nd gear slots is only 2 washers deep right? not across entire dog ear.

[crazy steve]

If the shift drum/shift forks are good, those dogs will engage about 2/3 of their height. And while those are bad, they still should be usable with proper grinding.

[motoman]

But... contact on 2nd gear slots is only 2 washers deep right? not across entire dog ear.

Not sure what you mean with the 'washer deep' thing. I can tell you though, my Venturer tranny has FULL dog engagement, flush with backside of slot with NO washer swap when I 'corrected' the dog-ears. Unusual compared to others, but possible machining measurments during fabrication resulted in FULL engagement of that particular assembly. That trannies dis-engagement issue was a result of shaft retaining bolt/washer coming loose and falling out......makes for a 'floating' sideways shaft assembly, consequently also partial engagement, rounding off the edge end of dogs.

[BillyRok]

Here is your answer -- Mack posted this a couple weeks ago. He mounted 2nd and 5th gears on the counter shaft after swapping the washer, then bolted the shaft back in its normal position in the case. You can see the shift drum and fork back where they normally sit in the case as well. When the transmission is shifted into 2nd gear, the engagement between 5th gear dogs and 2nd gear slots is as seen in the pic.

[IMG][/IMG]

[Fearthepack]

yes indeed that pic shows full engagement of the dog and the slots. i was under the impression only the rounded (worn) area of the dog makes contact with the slots, I will play with the shifting before I button things up to further any conclusion on the contact area. Thanks for your point of view seems like I have read a lot on contact points and formed this opinion that swapping the washer on 2nd gear doubles this tiny contact area of dogs and slots of 2nd/5th.

[Fearthepack]

With the pic it is hard to imagine the flex that must happen to start rounding off the dogs in the first place. Doesn't seem to be any where near the movement internally to cause the rounding of the dogs. But.......... it's there somewhere.

[BA80]

Do it the way you think will work, then go back and do it the way we KNOW it works.

Let us know how it turns out.

[Fearthepack]

No just looking at the big picture trying to understand the workings to see weaknesses vs strengths. I'm on XS1100 side always. it's help is monumental

[Fearthepack]

This is where my confusion set in.... post #5

http://www.xs11.com/forum/showthread.php?t=16390&highlight=replace+gears+grinding

[BA80]

trbig was just using the washer to show how little of the dog engages BEFORE moving the washer to the other side of the gear. That washer isn't even part of the transmission it was meant merely as a visual aid.

Sorry if I came off as a smart a$$, it's just me.

[Fearthepack]

All good! I'm going to just install 2nd with washer swap and 5th on the counter shaft, put back into the bike with shift fork to see how much of dog ear really contacts the slots.............. I'm guessing not a lot, would be nice to be wrong in this situation.

[Rasputin]

The wear on the dogs comes from the motion of them shifting in and out of gear. Once it is solidly set in gear, it will not slip. The things will take millions of gear shifts if they all were 100% efficient. They are not and the riders ability does create a part of the problem.
Thing is that thousands before you have had the issue and have fixed it using the advice here. Miss a couple of shifts or get lazy shifting and all bets are off.

[Fearthepack]

Indeed. I'm not questioning the fix (i already performed it the dremel way) it's just I was scared to work on the tranny and put it off! Now I find it a little fascinating so instead of just putting it back together I'm getting a good handle on how everything works together in there and study it's week links.