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| transmission, popping out of 2nd http://www.kawi2strokes.com/forum/viewtopic.php?f=14&t=13350 |
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| Author: | 2stroke [ Wed Mar 28, 2018 7:01 pm ] |
| Post subject: | transmission, popping out of 2nd |
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! |
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| Author: | demus [ Wed Mar 28, 2018 8:20 pm ] |
| Post subject: | Re: transmission, popping out of 2nd |
Pictures help... sounds buggered to me, but I’m no expert. |
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| Author: | Ja-Moo [ Thu Mar 29, 2018 8:32 am ] |
| Post subject: | Re: transmission, popping out of 2nd |
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. |
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| Author: | 2stroke [ Mon Oct 22, 2018 4:31 am ] |
| Post subject: | Re: transmission, popping out of 2nd |
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.... |
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| Author: | 2stroke [ Mon Oct 22, 2018 4:32 am ] |
| Post subject: | Re: transmission, popping out of 2nd |
Also I will try and add some pics later today |
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| Author: | demus [ Mon Oct 22, 2018 6:47 am ] |
| Post subject: | Re: transmission, popping out of 2nd |
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 
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| Author: | H2RTuner [ Mon Oct 22, 2018 8:22 am ] |
| Post subject: | Re: transmission, popping out of 2nd |
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. |
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| Author: | 2stroke [ Mon Oct 22, 2018 5:25 pm ] |
| Post subject: | Re: transmission, popping out of 2nd |
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..... 
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| Author: | H2RTuner [ Mon Oct 22, 2018 7:48 pm ] |
| Post subject: | Re: transmission, popping out of 2nd |
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. |
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| Author: | Ja-Moo [ Mon Oct 22, 2018 8:29 pm ] |
| Post subject: | Re: transmission, popping out of 2nd |
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. |
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