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Gear Slippage ... help!

  • Thread starter Thread starter bdub416
  • Start date Start date
Any resources? I've used BikeCliff's website quite a few times for other things (if you end up reading this, thank you by the way!), but haven't seen a write-up for tranny related work.
 
bdub416 said:
Any resources? I've used BikeCliff's website quite a few times for other things (if you end up reading this, thank you by the way!), but haven't seen a write-up for tranny related work.
Click to expand...
None that I know of. I suggest downloading a manual.

Basically, you need to pull the motor, then break it down by removing the heads, cylinders, clutch, pistons, etc. Basically take it apart to the cases. Then split the cases and replace the gears. Reverse the process when putting it back together. Reference the manual frequently and use sealer where it says, toque to specs, etc.

If you've never done it before, it's not a one day job. You'll need to pay attention when taking things apart and put the different components and their fasteners into their own boxes so you don't get bolts mixed up. It's nice to have the clutch components in one box when you need them - you get the idea.

One more thing. I mentioned manuals more than once. Make sure you have one. The exploded views will come in real handy.

Read the manual several times before you tear into it and make sure you have your parts before hand, or you'll have it in pieces waiting. Even better if you get someone to help that's done it before.

It's not rocket science, but if you don't have any mechanical aptitude it might not be a job you want to take on. If, however, you can adjust your valves or rebuild your carbs, you can do this. It's no different, just digging a little deeper is all.

Motors are all basically the same. Once you see how it's put together you'll get a better feel for how they work. I'm generally impressed with the shifting mechanisms on motorcycles. Pretty cool stuff.
 
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hampshirehog said:
Second, pull the clutch off and check the gear change pawls and springs (I've never worked on a 450 - you might be able to do this without pulling the clutch) - might just need a clean or could be worn.
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My old 450 shifted like crap. I pulled off the clutch hub to have a look at the shift drum detent mechanism and found the pawl was out of place. Not sure if a screw came loose or if a hack mechanic had his way. At any rate, after putting everything back were it belonged the bike shifted perfectly.
 
You can keep the top end on and just split the bottom case. You will have to take off the clutch basket, most behind it, crankcase covers and of course all the crankcase bolts.
Get a manual
 
chef1366 said:
You can keep the top end on and just split the bottom case. You will have to take off the clutch basket, most behind it, crankcase covers and of course all the crankcase bolts.
Get a manual
Click to expand...

How hard is it to assemble like that? Thinking back to the 1100 rebuild, it seems like it would be a nightmare getting everything lined up by lowering the top end down with the crank still in the top case.

It sure would save a lot of time and effort.
 
I have opened my cases on both 650s, once with top end on and off. As for reassembly, it isn't any harder with head on. In a sense it was easier since I didn't have to worry about studs getting bunged up when flipped over. Generally, if you know topend is in good shape, no leaks, or poor compression, you can save yourself some time by leaving topend attached. If you are going full rebuild than obviously tear it all down.
 
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