So, question on the second gear issue.....

[Great White]

My bike is an 83 so it's prone to the second gear issues 83-84 are known for.

 

However, my 83 only has 31,000 kms on it (19,000 miles) and shows no signs at all of second gear issues. If I'm lucky, I'll only put another 3-4000 kms on it before winter.

 

This winter, the bike is getting torn down to have an 86 harness grafted on (for CLASS, Cruise and the 41R TCI) and VMax heads installed.

 

I'm wondering since the bike will be torn down anyways, if it's worth addressing the second gear issue which (to my understanding) is caused by a shim and circlip issue.

 

As my bike is very low mileage and has no issues, I'm wondering if I can prevent the second gear issues by replacing the circlip and shim.

 

With such low mileage on the bike, I'm kind of more in a "recall to prevent the issue" rather than "fix the damaged part" scenario. There is no "punch mark" on the gear housing like there should be if it was recalled, so it appears it's never been recalled or "fixed". I bought it from the original owner and when he listed off everything he could remember done to it (and he was pretty detailed) he never mentioned anything about 2nd gear being fixed either.

 

I've also read on the VMax forums that there is a shim kit for the gear stack as well that takes up the slack in the assembly and also helps to prevent the second gear issue. Here's a quote:

 

At some point, Yamaha started putting a shim in the rear transmission shaft that is associated with the 83-85 gear problem. This shim does not show up in the service manual or the Venture parts fiche. It is however in at least the 88-93 VMax parts fiche in 3 different sizes.

 

Part #'s:

90201-256K5-00 Washer, Plate UN $3.21

90201-256K6-00 Washer, Plate UN $3.11

90201-256K7-00 Washer, Plate UN $3.21

 

One of the most respected guys there that builds VMaxs routinely for people said it is a little known part. He said there is no guidelines on using shim, but he puts largest one in that will fit to take slop out of shaft. Shim pushes gears on shaft towards the thrust washer that is known to fail.

 

The VMax's are prone to developing a gear issue similar to early Ventures, probably due to harder shift points.

 

I am going to get a set of these and see how they work out. Under $10 bucks for a set, so it can't hurt.

 

for the transmission, it is part #25

http://www.vmaxforum.net/showthread.php?t=27263

 

It sure would be nice to address the issue before it starts and spend 50 or 60 bucks instead of 600 or 800 bucks.

 

So, worth it to pull the cases apart and change the shims or not?

 

Keeping in mind, I'm almost going to be at that point anyways.....

Edited May 28, 2015 by Great White

[Wizard765]

They usually start to go around 70 or 80,000 Kms.. If you do it before it starts to come out then all you have to replace is the split washer. You will also need a gasket set and the engine has to come out. In my opinion if you are planning on keeping the bike it is a worthwhile investment in time.. If you wait till it starts popping out then you may have to replace gears and shift forks or at least back cut the gears.. Frustration is that you can SEE the split washer when you take the side cover off but cannot get to it without pulling and splitting the engine