Something Failed, let’s find it! Transmission Analysis.

[Claviger]

Honestly, no, I believe properly assembled and installed, it's perfectly capable of coping. The Turbo and Supercharged bikes would annihilate transmissions regularly if they weren't up to it, and, well, it seems that's not the case.

 

[barbagris]

Time to get the 3D CAD system out Mr @Claviger - Drop in DCT transmission cassette. Or a BLOODY GREAT BIG ELECTRIC MOTOR with a 2300 cc generator.

 

[Claviger]

what is WPC ?
and since you seem to know much about transmission i got my trans back from robinson's industries with the standard improvement . went riding but I still have the "snapping noise in 5th from 2500 rpm when going uphill which is why I had it opened up and shipped to robinson in the first place thinking backcutting bigger grooves and circlips would take care of the situation
do you care to venture an opinion on this mysterious situation ?

I believe the problem we're having with 5th gear is associated with the shift drum, I'll post more when I can take pictures, but, if I'm correct, its an inexpensive fix though it does require splitting the cases.

If I'm right, it won't matter how many times you swap parts, pull it apart and reassemble, or what fancy machine work done, the bike will always have issues until the fault is corrected (it's not mentioned in the service manual). My theory explains why some bikes have repeated transmission issues, while most seem to go on and on and on without any issues at all.

 

[Paul Bryant]

I believe the problem we're having with 5th gear is associated with the shift drum, I'll post more when I can take pictures, but, if I'm correct, its an inexpensive fix though it does require splitting the cases.

If I'm right, it won't matter how many times you swap parts, pull it apart and reassemble, or what fancy machine work done, the bike will always have issues until the fault is corrected (it's not mentioned in the service manual). My theory explains why some bikes have repeated transmission issues, while most seem to go on and on and on without any issues at all.

I agree completely.
One has to cure the cause of the problem, not the result !

I also agree that the gearbox is inherently strong enough, IF assembled correctly ! And that is the catch, knowing exactly what "correctly" is.

We are following your journey closely here Rob, it will be very interesting to see just what has broken, and then of coarse .... why !

 

[Claviger]

The trick is going to be establishing a repeatable and accurate method of measuring end play of various items as installed.

Come to think of it this morning, the entire reason I justified having the motor opened and trans undercut to myself was because of slop going into 4th that would grind at high rpm.

All of my sybmptoms,every single symptom, can be explained by excess play in the shift drum. 3-4 shifts move two selectors, exacerbating any drum end play, the fifth gear rattle, the original problem in 2014/2015 resulting in rounded second gear dogs. All of it align as symptoms of a drum that’s not holding the forks aligned quite right. The shift forks looking straight but showing abnormal wear on one side of the actuating portion normally seen on bent forks, even the slightly notch feel my bike came from the factory with.

If I’m right (a big if), then I predict my drum is going to have some for-aft wiggle, and when shifting that wiggle will skew the fork and create abnormal loads not perpendicular to the direction of movement of the dog gears.

Can’t wait to get it split tonigt!!

 

[barbagris]

The trick is going to be establishing a repeatable and accurate method of measuring end play of various items as installed.

And you will need to have that aspect of life sorted IF you take a DESMO route. Shim, assemble - test - <bugger!> - disassemble - repeat as required.

 

[albertaduke]

I believe the problem we're having with 5th gear is associated with the shift drum, I'll post more when I can take pictures, but, if I'm correct, its an inexpensive fix though it does require splitting the cases.

If I'm right, it won't matter how many times you swap parts, pull it apart and reassemble, or what fancy machine work done, the bike will always have issues until the fault is corrected (it's not mentioned in the service manual). My theory explains why some bikes have repeated transmission issues, while most seem to go on and on and on without any issues at all.

I quote you " pull it apart and reassemble !!!!! me ... I do not think so I can only do basic stuff and at 10 hrs labor for disassembling the gearbox out of the frame by the shop at $115 an hour you can quickly see where it is going and I do not have a money printing machine .so it leaves me with the only option of staying out of 5th gear when riding uphill or stay out of the 2500rpm and up range ,

unless YOU feel like doing surgery to my rocket3 for entertainment. as you obviously have the knowledge and wherewith for this arcane science .
I 'll see you on the 16th for the RAA west for now I will baby the machine .

 

[Idaho Red Rocket 3]

More restrained a bit. Mine feels and handles like a big sport bike, it’s no harder to turn than my Daytona, it’s faster and I generally ride it as a big sportbike. Just going to dial back a bit.

Yeah sure. That won't last more than 2 rides. What would be the point ? May as well just sell it and ride a stock Roadster.

 

[1olbull]

Yeah sure. That won't last more than 2 rides. What would be the point ? May as well just sell it and ride a stock Roadster.

Or perhaps one just not modded to extreme?

 

[Dr.D]

Yeah sure. That won't last more than 2 rides. What would be the point ? May as well just sell it and ride a stock Roadster.

His intent to ride it more say is nothing more that mental masturbation.