Interchangeable parts from Venture to fix 2nd gear problem. (based on parts diagram)

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DreamV4

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If I am wrong, somebody will correct me. There are 3 possibly bad parts, creating 2nd gear problem:
1.fork
2. and 3. gears #14 (holes) and 13 (dogs)
#14 is identical in Venture, #13 is different, but can be (???? check pics on ebay) used if combined with #6 (5th gear pair)
5th gear ratios are pretty close 26/28 (1.077) teeth Vmax, 29/32 (1.103) Venture. 2.41% difference
Complete transmissions and separate parts are pretty cheap on ebay.
top is 92 Vmax, bottom is 83 Venture, gears are marked green
tr 95 vmax.jpg
 
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one2dmax

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Someone has arrived. The problem with 2nd gear is usually the dog engagement with 2nd and 5th gear pinions. Again, the teeth are almost never the issue. You can reuse 2nd and 3rd wheel gears from any trans but those aren't the problematic gears. Most of the rest can't be mixed and matched a part at a time. You swap in the entire PAIR of gear sets which will work. Some of the Venture forks will work on a Vmax trans and some will not. Again, swap them with the entire trans at the same time depending on the donor trans year and model (more critical when you start looking into the Royal Star gear sets).

Even with very similar gear teeth qtys the diameters of the gears vary between models so you can't again swap individual parts (other then what has been noted). When you get into the other RS models there are additional ratios you can get and SOME of the gears can be swapped around. Like we use the RS Tour Deluxe 5th gears which is used in our overdrive option. It will physically swap on the shafts but for proper dog engagement it requires undercut matching on both the dog and slot.

Another thing you want to use is the latest gen 1 (2007) for the most current parts that would make the best option (all parts will interchange with the 85-07's EXCEPT the few 85 recall transmissions). Specifically the segment on the end of the shift drum and the spacing washers to get the excessive slop out of the 1st wheel gear. We have a youtube video that goes over how to chose one. You could probably make one cheap if you looked hard enough or wanted to grind one yourself.

You have a LOT to learn on these bikes lol. I think you should start ONE thread and label it as cheap repairs/mods and use that to document all of your work. Put it all in one place that way.

Here's more pics
 

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one2dmax

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one2dmax

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one2dmax

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Various trans damage
 

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DreamV4

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Very interesting, thanks! Are dogs undercut from factory or you did them?
Based on the diagram, 2nd gear engagement happens by 5th wheel #13 sliding onto 2nd wheel #14
 
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one2dmax

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The factory does have an undercut but probably done with a dremil tool by someone like yourself. It causes uneven loading and excessive wear on the dog doing all the work. Our undercut is done with a precision indexer and the ramp angle is also changed to help pull the gears together better. The precision index to both gears lets it have the exact same load on all dogs thus making it a stronger trans.
 

DreamV4

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I would consider buying pair of gears from you if you sell them. I have to take apart transmission first and find problem.
 

one2dmax

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I would consider buying pair of gears from you if you sell them. I have to take apart transmission first and find problem.
My pricing is too much. It would double the investment you have in the bike. Plus I am not sure I want anything I sell to be tied back somehow with your cheap rebuild. It's not just the two gears to do it "right". You can search ebay for complete pairs of gear shafts and the ventures will work if you swap in that complete set as mentioned. You can get by pretty cheaply that way.
 

DreamV4

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I guess post #7 shows rounded dogs of 5th wheel (counted 26 teeth), which is probably first to die. This gear engages 2nd gear, sticking dogs into corresponding holes of 2nd wheel.
 
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DreamV4

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Sean, please verify previous post about 5th wheel
 

one2dmax

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Sorry for the late reply. The 2/5 gear is what typically wears and causes the gear to not hold under load. Both need replaced. But, you need to examine your trans when you get it removed to know for sure what all you need to replace (or repair).
 

DreamV4

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I believe 2nd wheel (holes) and 5th wheel (dogs) go bad (output shaft, going to drive shaft)
You said pinions go bad, pinions are on input shaft(clutch shaft)
Anyway thanks for your posts and pictures, I'll definitely need them.
 
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