1964 CB77 transmission and/or clutch issue in 2nd gear.

[Jlovvorn]

Your gonna need LM for that one. Glad it's getting better.

[apophis]

I just installed a new clutch. I had the 6 phenolic plates and 3 wire setup. Installed new discs and barett springs. clutch was fantastic, but, my 2nd gear problem is still there.

i can shift into 2nd at low rpm, ride 1/2 a block, as soon as I apply power the bike lurches. with a big thunk. there is a mechanical clank and the bike takes off. this happens shifting up or down only when the ending gear is 2nd . fine until I apply power, then clank (once) a hard lurch and its fine.

the only way i can describe this was if it was in gear and those big teeth on the side of the gears that make the gears sync together jumped one big tooth. went to the next one, then is fine.

if you are turning a corner, the lurch breaks the tie loose a second when it clanks.

everyone told me this was a clutch issue that would go away when I changed it.

obviously a transmission issue.

i havent disassembled a 305. I assume I have to remove the engine from the bike to get the gears and have to tear down the whole thing to the last bolt and the repair manual is terrible.

before i beat it to death with a hammer, is there anything else that it could be?
and are 305 transmissions interchangeable? are cl77 and cb77's the same gears?

[LOUD MOUSE]

Shift fork, roller, drum, drum keeper and maybe the gears.
The trans you mention are the same. .......lm

I just installed a new clutch. I had the 6 phenolic plates and 3 wire setup. Installed new discs and barett springs. clutch was fantastic, but, my 2nd gear problem is still there.

i can shift into 2nd at low rpm, ride 1/2 a block, as soon as I apply power the bike lurches. with a big thunk. there is a mechanical clank and the bike takes off. this happens shifting up or down only when the ending gear is 2nd . fine until I apply power, then clank (once) a hard lurch and its fine.

the only way i can describe this was if it was in gear and those big teeth on the side of the gears that make the gears sync together jumped one big tooth. went to the next one, then is fine.

if you are turning a corner, the lurch breaks the tie loose a second when it clanks.

everyone told me this was a clutch issue that would go away when I changed it.

obviously a transmission issue.

i havent disassembled a 305. I assume I have to remove the engine from the bike to get the gears and have to tear down the whole thing to the last bolt and the repair manual is terrible.

before i beat it to death with a hammer, is there anything else that it could be?
and are 305 transmissions interchangeable? are cl77 and cb77's the same gears?

[Jlovvorn]

Getting at it is not that bad. It's 50 years old, so a worn out transmission isn't unexpected.

Throw the stock manual away. Get the Bill Silver book and read it.

Takes less than a day to pull the engine out. The sloper design makes it easy.

You can flip it over and take off the bottom end without disassembling the top end.

There are a lot of threads here about the process.

I just took a similar 160 engine all the way down to the last bolt, and I am a complete idiot beginner. It runs great now and was well worth the effort.

The people here can talk you through anything. It's like having mission control at your fingertips.

[LOUD MOUSE]

I neglected to mention 14mm brass bushing and kick starter pawl plus seals. ......................lm

Shift fork, roller, drum, drum keeper and maybe the gears.
The trans you mention are the same. .......lm

I just installed a new clutch. I had the 6 phenolic plates and 3 wire setup. Installed new discs and barett springs. clutch was fantastic, but, my 2nd gear problem is still there.

i can shift into 2nd at low rpm, ride 1/2 a block, as soon as I apply power the bike lurches. with a big thunk. there is a mechanical clank and the bike takes off. this happens shifting up or down only when the ending gear is 2nd . fine until I apply power, then clank (once) a hard lurch and its fine.

the only way i can describe this was if it was in gear and those big teeth on the side of the gears that make the gears sync together jumped one big tooth. went to the next one, then is fine.

if you are turning a corner, the lurch breaks the tie loose a second when it clanks.

everyone told me this was a clutch issue that would go away when I changed it.

obviously a transmission issue.

i havent disassembled a 305. I assume I have to remove the engine from the bike to get the gears and have to tear down the whole thing to the last bolt and the repair manual is terrible.

before i beat it to death with a hammer, is there anything else that it could be?
and are 305 transmissions interchangeable? are cl77 and cb77's the same gears?

[apophis]

I have the engine out. upside down. I am stuck at pulling the magneto part off. I have 4 honda"flywheel" pullers and none fit it. on some of my honda's you can use a 60's VW lug bolt, but this is larger.

can I makeshift anything or do I need an specific puller?

also, I ordered both Bill Silver books on 6/25/13. Still don't have them. does it normally take this long?

[apophis]

back up and running. need to re-time the engine, but its alive again. shifts and seems fine so far. thanks for all the help along the way