Kawi2strokes.com Forum

Enthusiasts from around the world dedicated to the preservation and ritual flogging of the infamous Kawasaki 2-stroke Triples
It is currently Thu Mar 28, 2024 8:23 am

All times are UTC - 5 hours




Post new topic Reply to topic  [ 11 posts ]  Go to page 1, 2  Next
Author Message
PostPosted: Wed Mar 28, 2018 7:01 pm 

Joined: Wed Jan 18, 2012 10:36 pm
Posts: 166
Ive got my S2 down all the way...among other things, I want to address an issue I had with it not engaging 2nd gear sometimes.

Lets say I had just made a hard run on it thru a fun back road then came to a stop sign at the end... Id almost always miss 2nd gear after pulling off and find a false neutral, even if I was leaving the stop sign normally, and not trying to push it anymore.

Seemed worse if had simply held the clutch in at the stop.

So it never actually jumped out of 2nd....just didnt like engaging after running it hard. I had redone the change linkage bushings the best I could before, really no change.

Most of the dogs on these gears including the one that grabs 2nd, are rounded edges.....do these round ones also have any undercut at all like the square angular ones? I guess I should suspect the shift fork involved in that change as well huh?

Any input would be appreciated!

_________________
1972 S2 350, 1972 F9 350 Bighorn, 1975 KX400, 1981 YZ465, 1980 XT500 (Built for MX) , 1987 KD80, 1995 MZ Skorpion, TTR 125, 1994 KDX200 , 1978 Mobylette, 1985 KX350R-F91m (Frankenstein) and a Doodle Bug


Top
 Profile  
 
PostPosted: Wed Mar 28, 2018 8:20 pm 
User avatar

Joined: Wed Jun 13, 2012 9:00 pm
Posts: 971
Location: Eagle Wisconsin
Pictures help... sounds buggered to me, but I’m no expert.


Top
 Profile  
 
PostPosted: Thu Mar 29, 2018 8:32 am 
Site Admin
User avatar

Joined: Tue Jun 07, 2011 6:37 am
Posts: 10460
Location: Rio Rancho, New Mexico
No undercut from the factory. The tranny has had a hard life I guess. Check the forks for bend and burning. And probably a shimming when you get the repair parts.

_________________
Twist the throttle, tilt the horizon, and have a great time. What triples are all about...........


Top
 Profile  
 
PostPosted: Mon Oct 22, 2018 4:31 am 

Joined: Wed Jan 18, 2012 10:36 pm
Posts: 166
Briefly if you would please..shimming...what would you shim exactly..between the gears? ...and how would you know when to use thicker or thinner shims?
Ive never done that....but i have another bike that would probably benefit....

_________________
1972 S2 350, 1972 F9 350 Bighorn, 1975 KX400, 1981 YZ465, 1980 XT500 (Built for MX) , 1987 KD80, 1995 MZ Skorpion, TTR 125, 1994 KDX200 , 1978 Mobylette, 1985 KX350R-F91m (Frankenstein) and a Doodle Bug


Top
 Profile  
 
PostPosted: Mon Oct 22, 2018 4:32 am 

Joined: Wed Jan 18, 2012 10:36 pm
Posts: 166
Also I will try and add some pics later today

_________________
1972 S2 350, 1972 F9 350 Bighorn, 1975 KX400, 1981 YZ465, 1980 XT500 (Built for MX) , 1987 KD80, 1995 MZ Skorpion, TTR 125, 1994 KDX200 , 1978 Mobylette, 1985 KX350R-F91m (Frankenstein) and a Doodle Bug


Top
 Profile  
 
PostPosted: Mon Oct 22, 2018 6:47 am 
User avatar

Joined: Wed Jun 13, 2012 9:00 pm
Posts: 971
Location: Eagle Wisconsin
2stroke wrote:
Briefly if you would please..shimming...what would you shim exactly..between the gears? ...and how would you know when to use thicker or thinner shims?
Ive never done that....but i have another bike that would probably benefit....


Go to the resource site and search transmission shimming, lots of info there.
Time, money and patience are needed and not necessarily in that order :thumbup:


Top
 Profile  
 
PostPosted: Mon Oct 22, 2018 8:22 am 

Joined: Thu Jun 09, 2011 11:25 am
Posts: 3137
Usually, the rounding of shift dogs is caused by not enough clutch release free play. The clutch doesn't fully disengage, and the dogs drag against each other, instead of freely engaging each other.


Top
 Profile  
 
PostPosted: Mon Oct 22, 2018 5:25 pm 

Joined: Wed Jan 18, 2012 10:36 pm
Posts: 166
Thanks. I looked at things again...as far as shift forks go, the center one looks like it has some wear....it doesnt feel as bad as it looks, but you can see some blueing on it as well as some wear and damage.

The other two dont have anything like that on them.

I could put the thing back together and it would run and go, just wanted to see if I could improve things a little. I tore it down just because I never had this one down all the way.

Here is a pic of the damaged fork---its the center one that goes around the shift drum, not sure if that has anything to do with 1st to 2nd....as far as sourcing parts, I cant find a NOS center fork, I figure I will buy a while used transmission set...gears, forks etc and choose the best of each.....

Image

_________________
1972 S2 350, 1972 F9 350 Bighorn, 1975 KX400, 1981 YZ465, 1980 XT500 (Built for MX) , 1987 KD80, 1995 MZ Skorpion, TTR 125, 1994 KDX200 , 1978 Mobylette, 1985 KX350R-F91m (Frankenstein) and a Doodle Bug


Top
 Profile  
 
PostPosted: Mon Oct 22, 2018 7:48 pm 

Joined: Thu Jun 09, 2011 11:25 am
Posts: 3137
There are people that add a hard face weld to the face of the fork, and repair them, as long as they aren't bent.

Put the transmission back into the case and load the shafts outward, then, see if the fork is bent, or just worn. In loading the shafts, simply pull them to the side when in position and make sure they are in the proper position, as if the clutch and sprocket were both installed and tight.

You asked about "shimming", if you look at the sides of each gear, there is a circlip and a washer, or, "shim", then, the gear. There are different thicknesses of shims, to move one gear closer or further away from a gear it is engaging with. Shimming is getting all the sliding gears adjusted to work best with all the fixed, non-sliding gears.

BTW, once you get it all back together, I have found that regular automotive gear oil for car stick shift transmissions and differentials, 85W-90, or 90W-140, has always worked well for me. Sounds like it is too heavy a viscosity, but, gear oils are numbers rated twice their actual engine oil weights. so, a 90W gear oil is the same as a 45w engine oil.

If you can, please give us a couple of pics of the two gears that engage together, with the worn shift dogs, so we can figure out how bad they are.


Top
 Profile  
 
PostPosted: Mon Oct 22, 2018 8:29 pm 
Site Admin
User avatar

Joined: Tue Jun 07, 2011 6:37 am
Posts: 10460
Location: Rio Rancho, New Mexico
You need the gears also. The only real way the forks wear is if the gear is running against them, which is what happens when the dogs are worn/rounded.

_________________
Twist the throttle, tilt the horizon, and have a great time. What triples are all about...........


Top
 Profile  
 
Display posts from previous:  Sort by  
Post new topic Reply to topic  [ 11 posts ]  Go to page 1, 2  Next

All times are UTC - 5 hours


Who is online

Users browsing this forum: No registered users


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Jump to:  
Powered by phpBB® Forum Software © phpBB Group