Fixing 2nd gear

[mrfunny107]

Hey guys. I just tested out my handy work in splitting the lower case of my 93 600. I had 2 problems.

1. the bike was stuck in 3rd gear.
2. popped out of 2nd under load.

this is what injured the bike.



That little chuck that cracked off jammed up the entire gear selecting mechanism.

So rode the bike shifts good and so on. But when I gunned it in 2nd it still slipped under load.

I bought a used gear set from ebay off a 2001 750 as well as shift forks.

When I had the motor apart and the gears out, to me they looked fine. But I guess not.

Does anyone have an example "picture" of what a good and bad gear looks like?

THanks!!!!!!

[maniac1886]

they are called "dogs". When a fork goes, if left untreated, will cause the Dogs to go and when they do, just changing the fork no longer becomes applicable (its not always the fork though, missing gears will grind the dogs down among other things.) So Dogs.... Look at the side of the gear, you will see what almost looks like a cube raised up off the side. Those cubes lock into the raised edges on the adjacent gear. You will see that the corners of them are probably shiny and rubbed round. Once they round off.... Its toast.

This isnt Kat gears but illustrates what im talking about.



those lock into these



you will see that they are both worn down, rounded, and shiny.

TOAST

[mrfunny107]

I don't recall them being shiny at all but this is the only thing I can think of that would cause it pop out of gear

[shpielers]

Bent shift forks will cause that too. Might not have to be visibely bent for it to happen, haven't pulled one apart yet meself.

[mrfunny107]

So bent another shift fork...





Also the dogs are all gone...







I wonder if the gear in the 2nd and 3rd pic are still good. The edges are rounded a bit but maybe still usable?

Pulling the motor and splitting the case literally took 3 hours. Amazing how exponentially faster doing something the 2nd time is!!!!!!!!

[ZookRick]

Just replace it while you are in there or you might end up having to split the cases again.

[mrfunny107]

Its sad that if I replace both gears with NEW gears its literally going to be about 1/3 of what I paid for the bike...

[ZookRick]

why are you buying new gears? just buy a used set off ebay

[maniac1886]

chances are a used set on ebay is just about as bad. Bought a tranny off ebay to fix 2nd gear in a cbr, new tranny did the same thing. Thats where I learned that it was the dogs.

[mrfunny107]

http://www.ebay.com/itm/SUZUKI-KATAN...3D380730235280'

These guys apparently provide an undercutting service. BUT I wonder if they need a salvageable gear to do so?

[shpielers]

Doesn't sound like it from the way the add is written. Call 'em. Can't hurt.

[maniac1886]

+1 on undercuts. Make those dogs bite like pitbulls. I'm not sure if you need not worn ones either. I'd call, its quite possible they can cut the ones you got

[mrfunny107]

They replied to my message. They said chewed up gears could be undercut still.

[shpielers]

They replied to my message. They said chewed up gears could be undercut still.

Awesome that's good to know for future reference. Thanks for letting us know!

[maniac1886]