Shifting fork problems

[Jim G]

I was riding my 66 305 superhawk with my wife a few weeks ago when it popped out of gear and keep clicking until we stopped. Upon stopping the kick starter would not budge. I've since taken the transmission apart only to find the third gear journal and the shifting fork to be badly damaged. The shifting fork was ground down, material transfered/deposited on the gear journal and the shifting for spread out.

I have all the parts to repair it but what bothers me is how did this happen and how can I prevent it from happening again?

Please advise

Jim

[Ovrman00]

Hi Jim,

I'm wondering if my bike is having the same issue that your bike had. I also have a '66 305. I have been thinking that my bike might be having and issue with the external (for a lack of a better word) parts of the gear shift mechanism, but after reading your post I am thinking it could be an issue with the forks.

When your kickstart wouldn't kick forward, would your gears still shift, and the crankshaft still turn? Would your tires not rotate in gear?

Thanks.

[davomoto]

Gentlemen, use the search function on this site. They are many threads on proper transmission set up. Get very familiar with the process, and you may want to X the gears while you're at it.

[Jim G]

Guys

I did do more searching and studied the trans components I removed. To answer Overman00, here is what mine did. The transmission was completely locked because the damage inside the fork would no longer allow the gear to turn since the journal was severly damaged. Once I disconnected the drive chain between the clutch and the crank I was able to turn the crank shaft over.

What I think caused my problem was a combination of worn gear dogs and it becoming disengaged while traveling at about 50 mph. The gear dogs are shaped such that once they engage they are suppose to draw towards each other. Mine were pretty flat and sqwared off on the third gear. When this happended, the gear journal that rides inside the shifting fork put siding loading pressure on it and damaged it. The result was material from the shifting fork transfered into the gear journal. It also bent my shifting shaft the shifting lever outside the side cover attaches to. I didn't realize this until I tried to put the cover back on. It cost me about $150 to buy used trans gears and the necessary gasets and seals to repair it. I have the engine back together but now I'm getting the frame powder coated since I've got it stripped down this far.

Let me know if you have any other questions. I'd be glad to help you with what I've learned.

Tx

Jim G