Second gear fix

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Ga2wheels

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New here to this forum, lot of good info here. Have an 88 that has had the second gear problem since I purchased it. Still rideable but can stand not being able to hit second hard since it will slip out.
Have the engine out and about to get it on a table flipped to access the bottom end.
And advice would be great. Task list while engine is out:
Fix 2nd gear. Best to use new gears or get them undercut?
Check and adjust valves if needed
Replace clutch
Replace all crankcase oil seals
Repaint engine
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Sure. best to email me at [email protected]

I've attached a few example pics. We also offer an overdrive 5th option as well.
 

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Thanks as soon as I get to the transmission I will contact you.




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Plenty surprises so far on diss-assembly.
The clutch spring seat was installed by a PO upside down so the spring could actual walk off center. That’s why the clutch is starting to slip. Only 1/3 of the spring tabs were compressed.
Also the clutch basket main nut was barely more that hand tight. (At least the lock washer was engaged)
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Well, you have it disassembled. Time to totally-disassemble it to fix whatever screw-ups the P.O. idiot made. Take plenty of pics & I hope you are consulting the factory manual for wear tolerances and the proper sequence of assembly.
 
The clutch plate are with in spec and very close to new spec. The spring however is not at least on half the spring ears.

Split the cases, was much easier than I thought. Figured I would struggle with it but once it was pryed in the right 2 areas it lifted right off.

I can see the second gear issue, dogs are rounded and I don’t think the second gear wheel should have this “stepped” look.
When you apply pressure you can feel the separating.
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And I was hoping no PO had made it in this far into the engine. But missing washer between bearing and 1st gear wheel on the middle shaft.



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Well that’s good to know, seems like there is room for that washer. More movement in that 1st gear than I would like.



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Well that’s good to know, seems like there is room for that washer. More movement in that 1st gear than I would like.



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Get all options of the washer and when you put the cases together ensure the gears rotate without any resistance. I once put in a washer that looked good on the bench with one case half removed, but when the whole set was assembled, it turned out to be too thick. This resulted in the gears not moving freely when I check the gearbox with the two case halves assembled.
 
Yeah I have made that mistake once before and now always run through the transmission through a dry run with the cases back together before any sealant/gaskets are placed and it gets bolted back together


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