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Hey Guys,
First some background info on my bike- It's an '81 GS550T model. Picked this up as one of those "garage finds been sitting for 5+ years" deals. I have never heard it run, nor have I ridden it. PO who sold it to me said it had a 2nd gear trans issue- would grind / fall out of gear and that's when he stopped riding it. He had purchased a complete used trans for it, and was going to rebuild it, but lost interest so it sat. He gave that to me also with purchase of the bike. I have the case separated and inspected the gears on the trans. I don't see any chipped teeth or severely damaged components. The service manual says worn shift forks are usually the cause of falling out of gear, so I have been looking closely at them. They list the service spec as the width of the forks at 5.30 - 5.40 mm with a limit of 5.20 mm. My current forks measure about 5.29-5.31 for all 3. The one in the used trans measure about 5.25-5.27, so my current forks are actually better than the "new" used trans.
I have fitted each fork into each gear, and even though they are not below service limit, there is some side to side play in the fork to the gear. I'm wondering if this is normal? I have not put a feeler gauge between the fork and the gear, but it does not seem like a snug fit. What would you guys recommend I do? Thanks in advance for any advice!
First some background info on my bike- It's an '81 GS550T model. Picked this up as one of those "garage finds been sitting for 5+ years" deals. I have never heard it run, nor have I ridden it. PO who sold it to me said it had a 2nd gear trans issue- would grind / fall out of gear and that's when he stopped riding it. He had purchased a complete used trans for it, and was going to rebuild it, but lost interest so it sat. He gave that to me also with purchase of the bike. I have the case separated and inspected the gears on the trans. I don't see any chipped teeth or severely damaged components. The service manual says worn shift forks are usually the cause of falling out of gear, so I have been looking closely at them. They list the service spec as the width of the forks at 5.30 - 5.40 mm with a limit of 5.20 mm. My current forks measure about 5.29-5.31 for all 3. The one in the used trans measure about 5.25-5.27, so my current forks are actually better than the "new" used trans.
I have fitted each fork into each gear, and even though they are not below service limit, there is some side to side play in the fork to the gear. I'm wondering if this is normal? I have not put a feeler gauge between the fork and the gear, but it does not seem like a snug fit. What would you guys recommend I do? Thanks in advance for any advice!
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