flip it or pull it?

[AussiXS11G]

just to further confuse the issue....the boss (MP) recommends....
If your shift drum cam looks like this -



you should replace with one that looks like this



Part number

[Jonesy :-)]

I noticed the edge where you have your rule is raised, where mine is sort of flat and level with the rest of the gear slots......the plot thickens.
Thanks for the offer Brett, but don't worry about giving me your gear, I have a spare motor if needed, I'm just trying to fix this one buy engineering if i can, but its looking like I might have to open up the spare donk.
Eddy was going to check one of his for me, so it'll be interesting to see what he gets. But it does look like a PO has out engineered himself by maybe machining a bit off the gear
Edit
Brett
I just noticed your set square tisk! tisk! tisk!

[BrettS]

I had done a measurement of second gear alone and got just over 15mm so seems your gear is at least 1mm narrower strange. Maybe a P.O. thought that was a good idea??? Be interested to see the other side of your gear to see if the difference is visible.
You can have this gear set if you want but I would be sourcing some unscathed forks.

[Jonesy :-)]

It was nagging at me so couldnt wait till tomorrow, just ducked up to the shed and checked mine..........shaft shoulder tocirclip groove is the same at 17mm

The gear thickness is where it gets interesting at only 14 mm wide compared to your 16.5 mm

And with the 1mm washer leaves 2mm gap between gear and circlip.........now thats a recipe for jumping out of 2nd.........so to the boffins out there, are there different 2nd gears?

[BrettS]

Just sitting here looking at my forks and yours and pondering the question why the forks are rubbing. The fork on the right of your picture seems to be 2nd gear selector, rubbing on this fork I believe is not uncommon in a bike that has been slipping. Seems people will hold the shifter in second to stop it slipping and second gear cog is very close (almost surprising it doesn’t rub on a good gear set) my parts bike motor fork was the same but police motor was good.  To me the real mystery fork is yours marked I*. I believe that is the 4th gear selector far left and it seems much more unlikely to rub on 4th gear cog unless it is at somewhat of an angle. Makes me suspect a few things. You mentioned the pin on the fork shaft was damaged, could the fork shaft be bent or worn in some way allowing the fork to angle in. Or is the fork bent?

[Jonesy :-)]

Thanks Brett, I'll compare those measurements tomorrow

[BrettS]

Something I notice is your shifting forks have different markings than mine. Maybe nothing but both my sets of forks had from Right to left, right being 2nd 5th gear. Fork marked 1 on the right J on the left. Middle fork 2G left fork 3H
From what I can tell your fork marked I* should be the left fork on 4th gear

[BrettS]

Further to our phone call:
I get 17mm to the inside edge of circlip groove. 16.5mm 2nd gear+washer ( washer underneath with small square across hole)  With washer and gear on shaft it looks to me those measurements are correct with 1/2mm left and consistent with 1/2 mm play discussed when on shaft.
See pics

[Jonesy :-)]

4th gear done,  progress pic cutting off the  rounded edge of dogs

The gearbox problems continue, for the short time i had the bike running it had a gear rubbing noise in neutral and some non magnetic glitter was found in the sump. The rubbing on the selector forks explains the noise and glitter, but why? Looks like some shimming is required.

[Jonesy :-)]

side view would show it better

[excess.11]

Bryan, Andy’s video (linked in a previous post) has a pretty good explanation of swapping the washer for Second. He suggests you could do the job professionally by machining a groove to acomadate another washer so gear is not wearing onto circlip. I’m not understanding how that would work as the existing machined slot would then seem to be an issue. So I would like to take a look at what they did to yours one day.
Interesting that your dogs still wore out. Did they dove tail the dogs as well?  One story I got stated even with worn dogs just doing the washer swap and leaving the dogs as is stopped the slipping.
It’s strange that Yamaha put some angle on all the other dogs except second.

Do many people have trouble with 4th slipping?

Hers s a pic of a NOS 4th gear...can t see any stock chamfering on the dogs here...

[BrettS]

Bryan, Andy’s video (linked in a previous post) has a pretty good explanation of swapping the washer for Second. He suggests you could do the job professionally by machining a groove to acomadate another washer so gear is not wearing onto circlip. I’m not understanding how that would work as the existing machined slot would then seem to be an issue. So I would like to take a look at what they did to yours one day.
Interesting that your dogs still wore out. Did they dove tail the dogs as well?  One story I got stated even with worn dogs just doing the washer swap and leaving the dogs as is stopped the slipping.
It’s strange that Yamaha put some angle on all the other dogs except second.

Do many people have trouble with 4th slipping?

[Jonesy :-)]

Yeah, mine needs that (shimming) too
Gears are worn from rubbing in the area where washers/circlip are, further exaggerating the lack of engagement. 5th  and 2nd dogs and slots are finished now working on 4th gear dogs

[AussiXS11G]

back in 2002/3 when I first rebuilt mine,
the chaps helping/advising re spaced the gearbox so that all gears selected were fully engaged,
this required some shimming, and some machining - just saying......
Didn't stop me from buggering up second gear dogs by being heavy handed of course......

[Jonesy :-)]

Table set to 2.5 degrees for gear undercut