2nd gear sketchy

[redblk63]

OK, my "in the backyard for 30 years" 1963 CB77 is together and running! Thanks, LM, for the 4th over pistons and gasket set. I now have 18 miles on my rests odometer.

Problem is, the transmission "kicks out" of second gear most of the time. Occasionally it will drive in 2nd, but applying torque seems to make it either jump into neutral, or jump out/in/out/in, which must be wreaking havoc with the dogs.

Normal procedure is rev up in first, then double shift to 3rd. Wish my 2nd and 3rd gears were Xed, to make this a shorter jump.

My gearshift indicator is aligned to 11 o'clock. My clutch works great, after its 30 year+ slumber.

My first bike 1n 1967 was a Super Hawk, and I have had bikes since then, but never worked on a transmission. Has my time come?

I opened up the clutch-side side cover and removed the clutch to check the shifter action, and it shifts fine into all 4 gears + neutral, shifter pawl is registered correctly, etc. Anyone else have this happen to them, and find out what it was? Rounded shift dogs, worn groove for shift fork, bent fork, worn shifter cylinder, or...

Thanks,
Larry in Pasadena[/img]

[e3steve]

Well Larry, the first & foremost thing to try is shimming the transmission with offset cotters, as described in Bill Silver's red HONDA Engine Repair Guide. I have a similar problem, but intermittently. I once had a CB77 that jumped out of 2nd gear constantly; that was a missing finger off a selector fork.

Whatever the problem, the first move is to drop the motor & split the crank casings.

[rustywrench]

Well Larry, it looks as though you will soon get some experience at transmissions. You've already listed some common problems that could be your culprit. I'm going to stick my neck out here and suggest rounded dogs and/or a bent fork. If/when you do tear her down, Davomoto recently posted pics of the gears and yours should look like his. There are many of us here who can help with parts so don't be shy about asking and by all means, keep us informed of your progress as we all learn by others as well.............RW

[redblk63]

Thanks, guys. I'll pull the newly installed engine and split the case as soon as I can get to it. I may have to post some photos, as I would hate to misdiagnose, fix the wrong thing, and still have a problem when I reassemble. Oh yeah, I like the idea of a smaller 1-2 gap and a larger 3-4 gap, so I'll X the gears while I have it apart. With the stock gearing, 3rd is too close to 4th for my taste.
Thanks again,
Larry near Pasadena

[LOUD MOUSE]

Ya can get to all the trans parts without removing the cylinders/top end. ...........lm

Thanks, guys. I'll pull the newly installed engine and split the case as soon as I can get to it. I may have to post some photos, as I would hate to misdiagnose, fix the wrong thing, and still have a problem when I reassemble. Oh yeah, I like the idea of a smaller 1-2 gap and a larger 3-4 gap, so I'll X the gears while I have it apart. With the stock gearing, 3rd is too close to 4th for my taste.
Thanks again,
Larry near Pasadena

[davomoto]

Larry, just flip the engine over on your workbench, and you can seperate the crankcases with the top end installed. Remember the two nuts in the valley on the upper crankcase. Get a seal kit, and replace all of the seals while you're in there.

Davo

[redblk63]

Thanks. I'll just pull the side covers, "flip" the engine (these engines are heavy!), and split the case.

I took it for a 43 mile spin this morning in the local mountains. It is really running well, aside from 2nd gear. I believe the 305 cc motor seems to produce more power than my SL350 twin. I need to go out now and wash off the grit. There were a few stream crossings through gravel, and I do not have a front fender yet. (I may adapt a leftover fender from an old Matador.)

Larry