Help and guidance needed please.

Mate I recently went through an entire Engine Rebuild because of worn 2nd gear doggears and 2 selector forks.

From what I am reading it sounds you got the same problem.

The more you ride it will get worse. Mine started at 30000km and it was 51500km when I stripped the engine.

I got my entire gears undercut by a race shop and replaced the selector forks.

600 dollars for the machining and 280 dollars for the 2 selector forks.

If you take it to a mechanic they will charge you around 50 hours of labour.

I did it with a mate. It is not a one man job.

The good news is if you decide to strip the bike that could be a great time to change your pistons to hi compression, get your cam ground to a more aggressive profile, get the head port and polished and plenty more while you are already there.

I know it feels horrible and I lived with my bike like that for 3 years...

Let me know if you need any help. Just been through it my self and yeah it sucks...
 
I'm beyond upset about this... This should not have happened this early into thr bikes life... Period.

So you lads think I'll be okay to do my ride from Ontario, Canada to Myrtle Beach, US?

Its about 1600km one way.
 
Tank said:
I'm beyond upset about this... This should not have happened this early into thr bikes life... Period.

So you lads think I'll be okay to do my ride from Ontario, Canada to Myrtle Beach, US?

Its about 1600km one way.
Click to expand...

Mate I ride 20000km like that. A you keep using 2nd gear the doggears keep rounding more and it will stay slipping easier and easier under less load.

A mechanic will tell you to put your bike on.a trailer and bring it to them immediately... What is happening is the dog gears are losing their edges. Tiny tiny filings.

The only real danger is being in second gear and depending on your bike to pull you out of a situation.

As for your 20000km to early comment. Mate mine happened at 30000km 2 months out of warranty. You know what Triumph said?

"How long do you expect the bike to last?"

The gears should last at least 2 engine rebuilds which in my books that is around 200000-300000km depending on how you ride (Racing conditions excluded)

When I got the technicians undercut my gears (best solution do not ever put the sane stuff in there) I asked what the problem was and why it happened.

They said Triumph original gear setup is very flat like what you would use on a 1000cc bike. With Undercut gears this problem will not happen again.

As I said don't hesitate to ask mate. I lost sleep for 3 years before fixing the bike...
 

It's ridiculous eh.... I'm half tempted to take this ***** in to a Harley Davidson dealer and trade it....

Beyond bull****.... I think it would be different if it was a cheap and quick fix but it's not.....


So you think I'd be okay to keep riding it, skipping to third where possible?
 
It's a beotch Triumph forgot how to build a transmission. Or they are making the parts on old worn out assed machines they've been using since 2005.
 

I did for almost 4 years. The problem gets worse as you keep putting the bike under load in 2nd gear. First the dog gears go then the selector forks.

If you stop gunning the 2nd gear your bike will ride forever but yeah still knowing there is a problem will eat you from the inside...
 
Here are some photos of the rebuild






Undercut Doggears and new Selector Forks





Don't give up man you can do this and you will end up learning a lot and have a much better bike!

Some more fun photos






You see there is light at the end of the tunnel
 


Any pictures of the damaged gear next to the new gear?
 
Tank said:
Any pictures of the damaged gear next to the new gear?
Click to expand...

There is no new gears. What they do is regrind the dog gears with 4-6 degree angle rather than 'em being straight and slipping at first bit of wear.

Below are photos of the gears before the fix.








As you can see the dog gears are rounded on 2nd gear and they are very flat on the rest.

They should have never built a gearing like this on a bike with this much torque.
 
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