1985 Transmission removal/diagnosis

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Tyboy11

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Problem: When more than 1/3 throttle is applied, it revs up accompanied with a ratcheting gear noise, in multiple gears. Previously posted in clutch section and realized it's not clutch after removal and re-installation. Suspect bent shift forks, shift drum damage or gear dogs worn.

I'm posting this here with some pictures along the way for others to use. I currently have the engine out and on the floor. I'm looking at what is necessary to pull the lower case to access the transmission components. The books I'm using jump around a lot and I'm afraid I'll needlessly remove something. If anyone has done this before and would like to chime in with what needs removed (besides clutch and basket) after engine removal to split the cases, or helpful lessons learned, I would greatly appreciate it.
 

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Pulled the case this morning and found an issue right off the bat. Just to recap my post in the the clutch forum, this happened while I was out tuning the bike. I had just replaced my 152.5 main jets with 150's and was out seeing the results. It felt great and decided to leave the next light fast and see what it would do. When I shifted into second, it revved up. I thought I missed a gear and shifted to second again, still revved up. It was still in gear and would move, as long as throttle input was low.

See below pics for what I have found so far. So all the damage looks like its on the main transmission shaft or middle shaft, whatever it's called.

Any thoughts on this???
 

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The fact you are doing the work reduces that greatly. She should be glad to have a versatile husband.
 
I am currently working with Sean on fixing this thing and also upgrades to the transmission while i'm in there. He definitely has a wealth of knowledge on these things.

I have opted out of doing the overdrive 5th gear. I searched quite a bit on here and didn't find any overwhelming accounts for doing the conversion. It seems people are kind of on the fence about it. If anyone has had the 5th gear conversion and has any input on pros and cons, please chime in?

I only drive this bike around town and to and from work, which is 65 miles round trip, only 10 of which are highway speeds.
 

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