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+--- Thread: Gen 1 2nd gear issue ? (/showthread.php?tid=22974)
Gen 1 2nd gear issue ? - ricks_1969 - 17-10-2015
RE: Gen 1 2nd gear issue ? - Batfink - 17-10-2015
On both my gen 1 I had the fun miss, or false neutrals. They normally meant I had to use the selector again. You said if felt like it missed but did it rev high?
Unless you chain is over spec on looseness or the rear sprocket teeth are extraordinarily worn I would count out skipping a tooth/teeth as the maths says it can't. Others with more than experience can help here.
I do know that, from experience with the gen 1, once plugs start fouling look further... Twice (do fife rent bikes) the best solution for me was to get injectors sonic cleaned. Solved theproblem instantly.
Probably didn't don't help but something is better than nothing lol
RE: Gen 1 2nd gear issue ? - ricks_1969 - 17-10-2015
Thanks for the quick reply,
It actually revved up ok after this event and the chain etc is fine, It just kind of felt like that sort of thing happened although I know it didn't, it just kind of felt like those sort of symptoms.
As quick as it happened it just picked up and revved normally right up thru to the next gear change, I later thought maybe it was due to my reaction of smacking the throttle open quite quickly because of the Inj cleaner and the previous issue with the plug.
I'm not sure about this 2nd gear issue tho, It didn't actually jump out of gear and need to be be clicked back into 2nd if that's what happens, after whatever happened it just picked up and took off without any need to click back into gear or anything..
I had planned to pull the injectors out and have them cleaned if this cleaner in the tank had no affect...
RE: Gen 1 2nd gear issue ? - ricks_1969 - 18-10-2015
Went out for a test ride this morning and unfortunately it is definitely the 2nd gear issue so it's motor out :(
I'll pull the engine out myself and take it to someone here in Sydney to pull the gearbox apart, I guess the gears will be sent out somewhere else to be undercut tho..
Damn bad timing tho I'll be having a shoulder reconstruction in the next few weeks with an 8 month recovery time, rego is up next month also so I'll just let it lapse for now :(
Bugger !!!!
RE: Gen 1 2nd gear issue ? - Maj - 19-10-2015
first thing that happens when it starts jumping out of gear is the shift fork has been bent slightly.
you can replace the shift fork and shaft through the shifter mechanism hole if its only done it once or twice , bit like key hole surgery, and usually works ok if you have only had it jump out of gear a few times , its when its done it for a while that the gear dog gets realy rounded
otherwise the bottom end comes off the motor without the need to dissasemble from top dowm, make sure anyone working on it knows this as its only a few hour job
RE: Gen 1 2nd gear issue ? - ricks_1969 - 19-10-2015
Good to know Maj.
It did it twice the 1st day and then the next day I took it back out to have a better chance to investigate it,
I tried several more times the 2nd day and it did it maybe 4 times or so, so probably done it only 6 or so times so far.../
RE: Gen 1 2nd gear issue ? - Camel - 19-10-2015
Change your fork before you round your dogs, otherwise your rounded dogs will bend your new fork!
RE: Gen 1 2nd gear issue ? - ricks_1969 - 20-10-2015
Yes,
I have other bikes to ride so there is no need to keep going on this one luckily,
so do you think there would be any real damge to worry about with the dogs at this stage ? I reckon its happened only 6 or 7 times but I was testing under heavy load etc, hopefully not hey ? :(
Cheers
RE: Gen 1 2nd gear issue ? - Camel - 20-10-2015
You can inspect them when you change the fork. There's just enough room to see whether they've gone too far. Keep in mind that if they are rounded you can still repair and undercut them so they'll be better than new.
RE: Gen 1 2nd gear issue ? - ricks_1969 - 02-12-2015
Well the gearbox is out and I've been told 2 of the 3 shift forks need replacing so might as well replace all 3, I'm ok with that but also told I have to replace 4 gears and should really also replace another 3 that are starting to show wear so 7 gears all up and so I don't need to revisit this at a later stage :(
I'll be getting the cost of this later today but expect it to be very expensive :( and also parts will be on back order so there is no way the bike will be back together this year...
I have spoke on the phone to a guy who can build up the dogs and undercut them and this would be a lot cheaper and quicker fix, I want to keep the bike and am wondering if the build up (if needed) and undercut is the way to go long term ?
The bike is a road bike and does cop a bit of abuse in the lower gears but certainly not punished...
What to do ?
RE: Gen 1 2nd gear issue ? - Maj - 02-12-2015
Cut them, no build up needed most times , if a gear is that bad replace it
most will have some witness marks but be surprised if you need 7 gears
later shift forks were better , all 3 is a good idea , and check the shift fork shaft is straight
RE: Gen 1 2nd gear issue ? - ricks_1969 - 03-12-2015
I took the gears in today to be undercut, the shift shafts are fine so that's good, I don't think there is any chance of getting it back together for about a month or so tho but at least I'll have a lot more confidence in undercutting over replacing with OEM, I don't want to have to do this again....