RGV slipping in gear

[badga]

Hey,

Just recently my bike has been slipping in gears other then 1st. Assuming that 1st gear gets locked in when clicking all the way down. When engaging other gears it goes in for a second and as soon as there is power driven to it, it clunks out of gear and in to neutral.

I changed the oil and gave it another go but only got worse. So this Arvo I striped it down and pulled out the transmission. Every thing looked fine except for the main gear which looks to have it's edges worn down.

So is this just a simple fix or does it sound like something else?

I took a vid of the transmission on the floor so I will post that when I get it uploaded.

Cheers

Badga

[badga]

rgv.mp4 - YouTube

Video of trans

[g0zer]

you arent looking at the right part of the mechanism. its the dogs inbetween gears that get rounded, and when they are rounded they drive the gears apart (sideways against the selector forks) under load.

the dog ring is parallel to the fingers.

[badga]

Had a look and the dogs don't look rounded, maybe I'm looking at it wrong?


This is what I'm talking about that's rounded.


Cheers

[g0zer]

Yes that is stuffed how did the edge get munched like that?

[badga]

Bad gear changing maybe or something.

Anyone got the gear locally.

[Gangus]

I've had gears recut by Ray easson.

[jules_1972]

Ray easson.

He wouldnt touch my Ducati heads!!
Off my list..


Whats the price of new gears?

[greggo]

I can't see all the pictures and vid cos I'm at work but if the engagement dogs are rounded (and sounds like they are from others comments) make sure you check the selector forks for wear and any signs these are bent. Wear will be seen as polishing or bluing at the edges where it rides on the gears. If it is, get new selector forks as well.

You may also want to make sure that the selector rod is striaght by rolling it on some glass or something. Sometimes these get bent in a crash and can take several months (on a track bike) to actually cause enough damage to jump out of gear.

[Gangus]

A couple of years ago he was rebuilding a race duke once a month. I'm pretty sure he was very unimpressed with the quality of components within the head/ motor.
As a consiquence it took 3 months for my job to get seen.

He has repaired a gearbox with 2nd gear gone aswell as one with 3rd cactus for me and they work sweet.
I'm considering getting the one out of my trackie to him over the off season for a spruce up.

[EEKNOWS]

This is what I'm talking about that's rounded.


Cheers

That appears to be the kick start idler gear which is supposed to look like that. Where you should be looking is the slot on the mating gear that will be rounded also. I use a gear cutter in Melborne and is $65 to undercut a pair of gears

[richarde]

^I agree with EEKNOWS. That particular gear is supposed to be like that, it is the kick-start idler.

Have you checked the selector forks for wear? Perhaps the gears aren't being pushed into mesh far enough. Does it do it on all gears or only some of them? The dogs commonly wear on second, but if it has suddenly started slipping out of more than one gear I would suspect a different issue

[HK31A]

Yes that is stuffed how did the edge get munched like that?

mmmmmm
being a constant mesh gearbox i thought the dogs mesh when changing gears not the gears

by the way with your shoot from the hip diagnostics you did check all the external ajustments before faultingthe g/box

hate to see all that work when it was just the gearlever shift rod out of ajustment or a stretched return spring on the selector drum

good luck

[g0zer]

sorry i assumed that pic was of the primary

[badga]

Took out the forks and could see slot better, it does seem to have rounded edges and fork wear.




Also checked the shifter shaft and seems pretty straight to me.
External adjustments are frequently played with and springs on selector drum look fine.

I dont really understand quite how this transmission works, but if 2nd dog mesh is stuffed would it cause the other gears to drop out and hit neutral? I think 3rd has slight rounded edges too. So basically I either gotta get the dogs repaired or purchase new dogs. The gear themselves look in good condition. Think I'll get some new shifter forks while it's out too.

Thanks heaps for the replies guys, been awesome help! Trying to get it back on the road for this weekend for MAD ride but I don't see it happening

[HK31A]

Took out the forks and could see slot better, it does seem to have rounded edges and fork wear.

Thanks heaps for the replies guys, been awesome help! Trying to get it back on the road for this weekend for MAD ride but I don't see it happening

badga - do youself a favour and take your g/box and selector forks to a bike shop at lunchtime or after work and ask them-does this looked f#@ked to you as its jumping out of 2 gear

then he will say - do you wheelie the bike

and you say - of coarse dont you

anyway then you will know for sure if there is a problem since you dont realy know what to look for- then you can get it ready for sunday

if you need new dogs iam sure someone here should have them lying around

good luck

[richarde]

It is hard to see from the photo, but the dogs don't look too flash. The dogs on second gear usually go first though, and it will tend to be an isolated problem with the bike dropping out of that gear. Worn dogs on second won't cause it to drop out of other gears. Shift forks would probably be the same although each fork does 2 gears so you could end up with issues with 2 gears from a shift fork issue.

The manual specifies shift fork to groove clearance limit of 0.5mm. If it exceeds this the manual recommends replacement of either the fork or the gear it meshes with and gives tolerances to work out which one needs replacing.

I have a spare gearbox sitting here that you can come and compare to if you like. It has a broken third gear and broken dogs on second so isn't any good. It might be the easiest to take it to a shop or something in the end if you don't really know what you are looking at

[badga]

Yer ill take it to expert so I can pin point the problem, was just hoping I could figure it out from here.

Any recommendations?

Ktec
Ray easson.

[richarde]

Ray has been pretty busy recently, not sure how busy K-tec have been. Either of them should be able to help you out