jumps out of gear.

[PBJ]

Okay we all know about the second gear problem, the washer at the end of the shaft is a metal that gets mashed flat and eventually the bike can't stay in 2nd gear.

 

Here's my problem i can put the bike into 2nd and excellerate as long as I stay below 3500rpms. The bike will continue to excellerate even up to 55 mph. BUT if I try to excellerate faster the tranny pops out of gear then back in a again. It will pop out again if i keep trying to push it but stay in as long as it'd below the 3500 mark.

 

I've talked about this with Skydoc 17 but Earl wasn't sure if this is the normal 2nd gear problem but because its in the second gear I believe it must be related somehow any idea what this might be???

[Venturous Randy]

It is not a matter of rpm as much as the amount of torque that is being exerted on the gearset. Just out of curosity, what is the last four of your serial number?

RandyA

[Pegasus1300]

From personal experience this is the beginning of the second gear problem and will get worse as time goes on until it wont stay in gear at any rpm/torque/acceleration.

[Yammer Dan]

From personal experience this is the beginning of the second gear problem and will get worse as time goes on until it wont stay in gear at any rpm/torque/acceleration.

 

 

:sign yeah that: Thats about the way my 85 is now but it will still pull the front wheel in 2nd .

[Dano]

Exactly as stated, this is just the beginning. Mine exhibited the same symptoms, the overlap between 2nd gear slots and 5th gear dogs becomes less and less till the HP overpowers the ability of the gears to stay meshed. Eventually the edges of both pieces become rounded to the point that they just slide past each other instead of engaging properly.

 

When replacing the split washer, it's best to do an undercut to the dogs and the slots to alleviate any potential problem in the future. You can see the rounded edge on the 5th gear dogs and the scrapes on the area between the slots on 2nd gear.

[MiCarl]

You can see the 2nd gear problem illustrated in the back dog (which is slightly out of focus) in Dano's first picture (which is actually 5th gear).

 

On the right side of it you can see the undercut angle that is supposed to pull the gears together. On the left you can see it rounded off. The dog should be symmetric. You can't see it in the picture, but the slots in the 2nd gear are probably also rounded.

 

Aw heck. Went ahead and drawed on the picture. Hope you don't mind Dano.

Edited February 6, 2011 by MiCarl

[PBJ]

It is not a matter of rpm as much as the amount of torque that is being exerted on the gearset. Just out of curosity, what is the last four of your serial number?

RandyA

 

 

Thanks everyone for the info. Thats what logic dictated it was but it's good to hear from those here that have the experience and knowledge. To answer the serial number question the bike is 0000110. But then I learned long ago on here that the bikes serial number was way below the 1450 when the split ring problem was found and changed.

 

Thanks again everyone for the info.

[Dano]

Not a bit MiCarl. I'm a gearhead and electrician, definitely NOT a photographer!

 

I couldn't find my pics of the undercut after I had ground them down using an adjustable angle drill press vice and careful hand maneuvering of the vise around the grindstone chucked in the drill, but you can see in the pics that the overlap between the dog and slot is not very much to begin with, maybe a couple of mm's, that's all.

 

Here's a couple shots of my drill press setup. I have not set the angle as of yet, because I had to grind all three dogs to eliminate the rounded edge and make all three the exact same dimension across the tops, but that allows you to have the same angle on the dogs and slots (as close as doing it by hand will allow!). After two years of running hard, I've had absolutely no slippage at all.

 

Of course, the first shot is of the split washer that wears out, you can see the groove worn into the inside edge.