Transmission advice sought - 1981 GS550 (link to pictures)

[Anonymous]

I've got a GS550 engine with the cases split due to a slipping second gear. My *plan* was to use a donor transmission in the good engine. After getting it torn down, it is now apparent that the planned donor transmission is in even worse shape than the current transmission.

I've heard rumors about getting transmissions undercut. If they can undercut a transmission, it would seem that they could again straight-cut a transmission to restore it to operation. ..

But .. I'll probably need a new shift fork anyway. And, if I'm buying a new shift fork, should I just buy two new gears and find somewhere than could press them on?

Ideas? Ooh! And pictures!

http://www.mitchn.com/tranny/

--Mitch

[Dink]

You need to replace that shift fork, I would do this and then check side clearences in the shift fork groove on the gear, if that clearence is to wide then replace the gear.
Dink

[Anonymous]

After a couple of busy nights, I've had time to order up a new fork tonight. I'll know in a week or so whether it helps.

Thanks!

--Mitch

[TheBigRed]

Hey Mitch

Ideas? Ooh! And pictures!

http://www.mitchn.com/tranny/

--Mitch

Mitch, I went up a directory to surf around your web pages a bit, and I did notice that your link to The GS Resources is www.gsresources.com not www.thegsresources.com. Just thought you might like to know so you aren't sending ppl out into a black hole on the net.

Amos

[Anonymous]

perl -p -i -e "s/www.gsresources.com/www.thegsresources.com/g" *.html

Done, and done. Or maybe I should register gsresources.com and set up a redirect to the new site... anyone interested in that?

--Mitch

[Anonymous]

perl -p -i -e "s/www.gsresources.com/www.thegsresources.com/g" *.html

Done, and done. Or maybe I should register gsresources.com and set up a redirect to the new site... anyone interested in that?

--Mitch

Like this ? ---->>>> http://www.crikey.com/ TheGSResources would be more famous than some reptile hugger

(why didn't I grab a bunch of domains 10 years ago? I'd be RICH now)

[Anonymous]

Hi all how where do i go for info on splitting the tranny,im guessing the motor must come out of bike,looking at a bike with bad second gear also ? thanks

[Anonymous]

I've heard rumors about getting transmissions undercut. If they can undercut a transmission, it would seem that they could again straight-cut a transmission to restore it to operation. ..

This is true - but why would you want to do that if undercutting is the same price? Basically, undercutting cuts a more of the dog further from the end. This then 'locks' the gears better. Probably not a good explanation, but the best I can do right now.

But .. I'll probably need a new shift fork anyway. And, if I'm buying a new shift fork, should I just buy two new gears and find somewhere than could press them on?

If your shift fork is bad, this may be the reason for the tranyy slipping out of gear. If the dogs are not fully engaged, then thye can pop back out. (Undercutting reduces this).

It's hard to tell from your pics, but I do see a bit of rounding on the ends of the dogs. While this is not optimal, it may not be the sole cause of your problems - the shift fork is very suspect.

I would reassemble with the old shift fork and note the positions of the gear dogs (2nd ) and see if they are fully engaged. (Note - do this all in the top half of the cases). Then, when you get your new shift fork, you can make some comparisons.

[Anonymous]

Hi all how where do i go for info on splitting the tranny,im guessing the motor must come out of bike,looking at a bike with bad second gear also ? thanks

Yes, the motor must come out. The cases must be split, that means the entire motor must be disassembled. I suggest you get a manual and read it several times.