2nd gear, revisited

simi_ed · July 14, 2010, 09:03:45 PM

OK, I guess it's my turn in the barrel

I was out over the July 4th holiday, riding with my wife on back; going up some 2nd gear switchbacks, when I noticed 2nd gear acting as if I was fanning the clutch, but with sharp slip/grab events. Shit!

I think I'm joining the 2nd gear club.

Any recommendations on who can do an above average job undercutting the gears? Anybody with experience have some advice? I've already found & digested the excellent write-up fowarded from the Yahoo list from 1999.

Thanks!

Flying Scotsman · July 14, 2010, 09:13:06 PM

I was told Gas by Gast so try them.
Looked at the website but did not call them yet.My 2nd pops all the way out at higher rpm 3rd goes in and out real easy it wont pop all the way out but it feels like the chain is jumping the sprocket.

racerrad8 · July 14, 2010, 10:12:44 PM

Quote from: simi_ed on July 14, 2010, 09:03:45 PM

Any recommendations on who can do an above average job undercutting the gears? Anybody with experience have some advice? I've already found & digested the excellent write-up forwarded from the Yahoo list from 1999.

Thanks!

Ed, Ed, Ed...

While I do not undercut the gears since they were actually done by Yamaha, after 87-88 I believe, I do have everything you need to make all of the required repairs.

Randy - RPM

simi_ed · July 14, 2010, 11:07:13 PM

Well, Gee... Since we're already gonna be in there ... Never mind, I'll PM.

Again, Randy comes through!!! RAndy, you're a true asset to us lucky FJ owners

Ed

RichBaker · July 15, 2010, 09:43:03 PM

Quote from: Flying Scotsman on July 14, 2010, 09:13:06 PM
I was told Gas by Gast so try them.
Looked at the website but did not call them yet.My 2nd pops all the way out at higher rpm 3rd goes in and out real easy it wont pop all the way out but it feels like the chain is jumping the sprocket.

That would be FAST by Gast......

Flying Scotsman · July 31, 2010, 01:00:17 AM

I was venting I didnt want to take over the thread with my problems.I am excited about geting these undercut gears even though they wont go in for a while.

fj1250 · August 12, 2010, 05:22:57 PM

Any time your into the transmission, try to find shift forks from a Legends car motor to replace the crappy short one the 1100's came with and the medieum length ones the 1200's came with.
Then send them out and have them CRYODIZED!
Also check for wear on your shift cam at second gear. Good chance you'll have some. Any wear on the cam, pitch it and get a new one.
The heavy duty shift detent spring is an excellent upgrade also.
Oh, the late model gearsets were undercut mildly at the factory by the same guy who machined the undercut off the original gears. If your tranny's out of the bike, don't dick around, replace the worn stuff, get it ALL undercut, and cryodoze as many of the parts as you can.
I own probably the slickest shifting FJ around, Just take some work to get it right.

MC

Motoguy · June 11, 2018, 09:14:36 AM

Hi all,
I was wondering what you ended up doing to resolve the 2nd gear slip? My bike started doing it after I swapped pods for the airbox and stage 1 jetting, I also did some clutch work and have been trying to blame my clutch.
I have been through my clutch quite thoroughly and am afraid that it is in the tranny. I am wondering what parts I am going to need to get ahold of to get my Kookaloo back.

Ride On!

Jeff

balky1 · June 11, 2018, 09:19:21 AM

Quote from: Motoguy on June 11, 2018, 09:14:36 AM
Hi all,
I was wondering what you ended up doing to resolve the 2nd gear slip? My bike started doing it after I swapped pods for the airbox and stage 1 jetting, I also did some clutch work and have been trying to blame my clutch.
I have been through my clutch quite thoroughly and am afraid that it is in the tranny. I am wondering what parts I am going to need to get ahold of to get my Kookaloo back.

Ride On!

Jeff

Contact RPM, I believe that could be the best thing to do. They'll guide you through the process.

Motoguy · June 11, 2018, 11:57:17 AM

Quote from: simi_ed on July 14, 2010, 09:03:45 PM
OK, I guess it's my turn in the barrel I was out over the July 4th holiday, riding with my wife on back; going up some 2nd gear switchbacks, when I noticed 2nd gear acting as if I was fanning the clutch, but with sharp slip/grab events. Shit! I think I'm joining the 2nd gear club.

Any recommendations on who can do an above average job undercutting the gears? Anybody with experience have some advice? I've already found & digested the excellent write-up fowarded from the Yahoo list from 1999.

Thanks!

I should have used the quote from this old post, it describes what my bike is doing now to a tee.

Jeff

Hi all,
I was wondering what you ended up doing to resolve the 2nd gear slip? My bike started doing it after I swapped pods for the airbox and stage 1 jetting, I also did some clutch work and have been trying to blame my clutch.
I have been through my clutch quite thoroughly and am afraid that it is in the tranny. I am wondering what parts I am going to need to get ahold of to get my Kookaloo back.

Ride On!

Jeff

RPM - Robert · June 11, 2018, 12:32:57 PM

I don't recall if the quote was the time Ed had to re split his case or not but I do know you would be better off fixing it right the first time. http://www.fjowners.com/index.php?topic=16690.0 Feel free to shoot us an email and I can work up a price quote for all the parts you need to fix it right the first time.

balky1 · June 12, 2018, 12:23:24 AM

Quote from: RPM - Robert on June 11, 2018, 12:32:57 PM
I don't recall if the quote was the time Ed had to re split his case or not but I do know you would be better off fixing it right the first time. http://www.fjowners.com/index.php?topic=16690.0 Feel free to shoot us an email and I can work up a price quote for all the parts you need to fix it right the first time.

This is just the best you can do because halfmeasures usually get you only half way there, ending more expensive in the end than it would be if you did right the first time.

Motofun · June 12, 2018, 06:38:28 AM

Motoguy...A "slip" or does it "jump" out of second? Big difference. A slip, especially after increasing engine power is likely just weak clutch engagement. This is not the fault of the clutch plates, rather the single diaphragm spring. One cheap way to address it is to double up the springs...it does make the clutch pull more manly, though.

oldktmdude · June 12, 2018, 06:44:41 AM

Quote from: Motofun on June 12, 2018, 06:38:28 AM
Motoguy...A "slip" or does it "jump" out of second? Big difference. A slip, especially after increasing engine power is likely just weak clutch engagement. This is not the fault of the clutch plates, rather the single diaphragm spring. One cheap way to address it is to double up the springs...it does make the clutch pull more manly, though.

Clutch slip, after a power increase is usually experienced in the higher gears i.e. 4th and 5th. Probably not unknown in the lower gears but a lot less common.
What you have described is the typical "second gear issue".
Regards, Pete.

Motoguy · June 14, 2018, 06:26:13 AM

I put in the Barnett coil spring pressure plate years ago when I felt a little slipping under hard acceleration. In addressing the slip/grab that I am experiencing I have gone to the green springs on the clutch, new steels and fibres and I eliminated both narrow plates with the help of a machinist at work. As a side bonus I now have "Kung Fu grip" that rivals GI Joe's with my left hand. I am going to order the required parts from RPM and tear into it pretty soon. Funny thing is that I don't remember any specific event happening to get this problem started. It seems as though it is jumping out of second momentarily and reengaging. If I don't let off the throttle it repeats. Really take a lot of the fun out of zipping around.

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2nd gear, revisited