4th gen gearbox rebuild (2nd gear issue)

Hi All,

I'm in a bit of a pickle :-(

I've got a 2nd gear issue which seems to be exactly the same as V4 Fanatics, here:

http://www.vfrdiscussion.com/forum/index.php/topic/72644-4th-gen-clutch-issues/page-1


First off, I am finding it next to impossible to craft a search term on VFRWorld that doesn't return a great swathe of seemingly unrelated posts, content, etc...

I've decided that I will need to have a look at my gears.

I have recently lapped the 8 front valves and over the last 5 years I've rebuilt/replaced most of my VeeFar.
I have the Haynes Manual, a garage, a fair collection of tools and a bit of an aptitude for mechanicing.
Point is, I'm no newbie

I am researching what I will need in terms of knowledge, special tools and tips to complete the following:
(assume I can remove fairing, tank, carbs, cooling system, exhaust system)

1. Drop the engine
2. Split the case
3. Inspect the whole transmission, identify issues.
4. replace gears, forks, dogs, bearings etc...
5. Put back together
6. Ride off into the sunset with a stupid grin on my face.

I am particularly interested in any videos of 4th gen work in these areas of the bike AND/OR any lists of parts & tools that someone may have done in the past...more as a reference and to verify I haven't missed anything.

Also, are there any products on the market that could strengthen my gear box. Titanium gears/dogs for example?

Any and all help appreciated,

Thanks,

Tim

 

Over here we have a tool store called HF, harbor freight, or hazard fraught, that has piles of crappy tools that usually break first time used, but they are really cheap. You may have a similar store in your country.

The Honda Factory Service Manual and the Common Service Manual have all the information you desire--the Haynes is the HF of manuals.

 

Really? I know it is less than thorough and I've certainly been spitting teeth when I've read things like "simply undo the...", but I've thought the Haynes to be adequate.

Would there really be much benefit to the factory service manual?

 

I'm hoping to have time to do this to a 5th gen motor this week end. Motor is already out, just need to split the case and get in to the transmission for 2nd gear analysis. Can share pics if I get in to it. First I'll be reviewing the Honda shop manual though.

 

I know there are some significant differences between 4th and 5th Gen, but any "inside" help would be appreciated.

Cheers, good luck and have fun

 

I got stuck in 2nd today. bloody thing wouldn't click into 3rd. so I'm going to strip down the gear selector mechanism this weekend. it may just be a simple case of the whole lot being gummed up.

 

That would be a bit of luck, hope it works out. In terms of engine hard parts the 4th and 5th aren't that much different. I think the 4th has the gear drives in the center of the engine, the 5th moved them to the end of the cam. Other than that and a little displacement, basically the same motor.

 

I didn't get round to doing the gear selector strip down. I hadn't realised that I need to drop the oil to do the job.

So, I'm going to order clutch pads, plates & springs and various gaskets...Do the selector mechanism strip down and clutch at the same time.

The annoying thing is, I have only just put that oil in there, so will have to syphon out as much as I can into a cleaned oil bottle and just filter the rest. Never a wise idea, but I can't justify another £30 oil change so soon after the last one.


New symptoms:
Have done 300 miles since original post.

Getting into 1st from 2nd is becoming difficult. I get the sound of the dogs not quite engaging, after several tries it eventually goes in.

I've noticed the surging happens in 3rd as well, but much less frequently.

In 4th & 5th (not 6th), I've noticed clutch slippage under hard throttle. Auto barn speeds, 8-10k revs (ish)


Any thoughts/suggestions greatly appreciated.

I will continue to update this thread in case it is helpful to someone in the future.