Slipping in and out of 2nd

[jakeolsen]

I just picked up this '86 550e. It runs great and looks great, but it slips out of second gear. Looking around on the net, it seems to be a somewhat common thing. My question is, where should I start to look first? Could it be something as simple as the clutch springs? So far I have also seen shift forks or a bad 2nd gear be the problem.

[Nessism]

Most likely its the shift fork(s) and/or the gear dogs as you already noted. You have to split the crankcase to get at the parts - not easy. One thing worth checking is the shift drum detent wheel which is typically located behind the clutch hub. On my first GS, a 450, some mechanical knob messed up the detent wheel so the bike wouldn't shift for crap. Putting all the parts where they belong fixed the problem. Hope your bike is similar but I doubt it.

[jakeolsen]

I figured that was the deal. Sure going to be some fun with that. I did get a good deal on the bike though, and its in great condition, so hopefully I'll feel its worth the headache in the end.

[chef1366]

Try a good sure shift by slipping the foot farther down the shifter and shift with the foot and not the toe.
Probably rounded dogs though.

[tkent02]

Second gear gets the most abuse, the most common gear to get the rounded dog syndrome.

People always shift the hardest into second.

Avoid using second much, and keep an eye out for a replacement engine.

Nice looking bike.

[jakeolsen]

Most of my driving is back roads with a speed limit of 50-55. So 2nd is not going to see a TON of use. I figure, even though it is a lot of work. It is not an overly expensive job to do. A new second gear only runs about $60.

[mushman]

I second the detent wheel diagnosis. My 1100 did the 1st to 2nd jump out of gear and after getting into the tranny I found the detent broken in two. Had the gears sent off to be undercut while I had things apart.

[Baatfam]

I figure, even though it is a lot of work. It is not an overly expensive job to do. A new second gear only runs about $60.

I'm not sure about the 550 motor, but I do know the 1100E motor...
I broke the trans on my drag bike two years ago.
I split the cases and took the trans to my motor guy, http://www.klemmeperformance.com/ to rebuild it.
Getting the gear may be inexpensive, but swapping it on the shaft isn't the easiest thing to do. Requires a press and some skill.

My 1100E street bike motor is on the floor now to have the trans replaced...
Same issue, popping out of 2nd under acceleration. Road it all last year like that.
I'm fairly certain it is worn dogs...the shift detentes look good.
I found a decent, complete stock trans on eBay cheap and I will just swap it out....that's the easy part.
Then I'll send the old trans to my guy and have the dogs reworked.

[jakeolsen]

Ok. So I took it out today for a little ride, a balmy 28F. When I said its slipping out of second, I was going based off of what the PO said. For me though, it is shifting into 2nd every time. The thing looks like it is low on oil big time though. I am going to drop the plug and filter, and refill. Looking at the sight gauge, I can just barely see the oil in the case. It seems to ride in second fine for me, maybe just a little stiff. I rode around the neighborhood in second up to 30mph, and didn't have any slippage or anything.

[Suzuki_Don]

You won't have any problem replacing the 2nd gear on either shaft on the 550 trans. I have just rebuilt mine and had all gears removed from both shafts except for 1st gear on the countershaft which is cast in one piece with the shaft (i.e. not removable). The only special tool you need is a pair of appropriate circlip pliers.




Countershaft stripped



Driveshaft stripped, bearing removed (not necessary as replacements are not available)



Driveshaft reassembled



My damaged 6th gear that needed replacement (you spend a fair bit of time in 6th)