Second gear fix...with a hammer

[myac455]

This one deserves a new thread.
As I had mentioned , I took my transmission apart to inspect the shift dogs.
I just pulled the shaft forward , gave it a wiggle and a tug , and out it came.
So far, so good.
The gears weren't bad at all, and probably would have lasted a while longer, but hey, I already bought the Dremet bits, per TC's early article. Part numbers are still good, and I was already there.
Couple hours later, I was ready to put the gears and shaft back . Of course, I flipped the second gear washer too.
Okay then. I tucked the second shift gear in behind the 5th pinion gear below, but then the other end of the axle was hitting the snap ring boss on the case, and wouldn't drop down for nothin'. After about a half an hour of fiddlin' with it , I took a break for dinner and a cocktail. Figured that would help.
Now ready to try again, I got to thinking. The only difference here is the shaft and second gear are a wee bit longer, due to moving the 2nd gear washer. Okay..got to try something. I put the washer back where it was, put all the gears on , and then was able to drop the whole assembly right down into place!
Of course, I didn't like the looks of the spacing, 2nd to 5th, and didn't come this far for nothing, so I took it back out and flipped the washer again.
Then I took my new Dremel tip, and ground away a little bit of the boss that holds the C clip for the bearing on the clutch side.
Now the axle end cleared the case, after a little push with the palm of my hand. Still wouldn't drop down all the way to go into the bearing. The axle is tight against the bearing now.
Getting tired of this s**t .
I took my hammer handle and gave the middle gear a little whack or two, and it popped down into place ,and into the bearing. A little bit of fork fishing and it was all functional again. Don't know how I'd get it apart again.
Now I ask you guys.
I must have read 6 articles about the second gear fix this way, and I never saw a word about this issue. Surely wouldn't want to do this job off a creeper. I know that much.
So , did anyone else ever have this issue, or does this kind of crap only happen in my world?

[bikerphil]

Yep, I have had to persuade a few gear sets back in with a mallet after the washer move, I have heard of other members having to do the same, maybe Marty? All it takes is a few thousands of an inch in the size of the gear set or the engine case to cause this problem, I have had many just fall right in too over the years.

Nice that you got her all back together.

[donebysunday]

()]-[ my dremel

I saw a little corner of the engine case keeping me from getting the gear set back in. A touch with the Dremel using the same stone I used for back cutting the dogs and slots worked a charm !

[myac455]

So it wasn't just my usual luck after all.
Still surprised I never read about this before now.
A casual, part time home bike mechanic would probably want to know about this beforehand.
Well, we're on the record again, guys...and in the search archives.
Been thinking about taking this thing apart again some day (instead of sleeping). I figure I could thread a longer bolt in that shaft, and tap in and up at the same time to get it started on the way up. Then maybe a flat screwdriver though the bearing and under the shaft, to persuade it some more.
I don't see why you couldn't put a little bevel on the end of that shaft too, up to the threaded hole. Just a thought.
One other note. I want to suggest looping a piece of mechanic's wire around the body of that middle fork, and fold it back one time around itself, before actually pulling the fork shaft out. It seems to be a lot easier to get that fork out of place, than it is to get it back where it belongs later on.
Thanks
Carry on...

[Radioguylogs]

No cutting for me

I was able to get mine back together without any forceful persuasion or cutting.

Then I saw that I missed something.....can't remember what it was....and I had to do it all over again. I remember it took a longer the second time (45 min instead of 15 min).

I also remember that the position of 1st gear on the shaft was important as I inserted the clutch end of the shaft. Then I had to slide first gear a little before the other end with 5th gear would drop down, fiddling with the forks along the way.