Transmission Blues, Near Death Risk, & Option to Replace / Upgrade

Mongler07

Turbocharged
Joined
Jul 20, 2021
Messages
983
Location
Colorado (Littleton)
Ride
07 R3 classic
As some of you know my trip to dragonmans was an epic disaster as far as my rocket was concerned.
I'm very lucky i did not wreck, i had the rear wheel lock up twice on the road at the end!
I always had 2nd gear pop out issue, so YOLO ill just skip 2nd. FINE. rode her for about 5K miles like that, no biggy
On a trip to dragonmans i got off the highway and the trans had an epic failure. I could not get into any gear but 1st and 5th. I limped it home after dragonmans. i found i was able to get it from 1snt into 2nd but i had to pop it towards 3rd and then back DOWN into 2nd and HOLD the shifter physically down, get up to 55mph and shift into 5th skipping 3rd and 4th. BTW if this ever happens to you, JUST CALL A TOW TRUCK OR TRAILER IT HOME.
some times it would sound like metal marbles jumping around THOUGH THE EARPLUGS AND HELMET AT 70MPH, not a wise idea
It started slipping INSTANTLY when this happened, before it started NO SLIPPING AT ALL. it must be so much trash in the oil that its in between the clutch holding it apart a bit?
SO having the rocket out of commission has be supper bummed out more than normal.
i remember you all telling me about a transmission specialist for the rocket that can back cut the dogs?
My question is, how much labor to pull the trans out? do i need to drop the engine out? can i do it in place? what options are out there to fix the wear on the forks? I want to do all the work myself and send out parts to whomever to have machine work done. Can i just drop the pan and what not, drop the trans out and see what needs to be ordered? Is there a kit? I'm not made of $ but im happy to pay for what needs to be upgraded.
Im supper bummed out hard, my BDAY is in a few days and i was planning on a ride on her but i guess ill just ride my ninja!
I'm sure when i drop the pan its going to have some supper bad carnage in there. Do you think i should flush the engine or anything? how much trash can go though? replace the oil pump???
If i have to pull the engine out its going to have to wait till winter or something later on.
 
You'll have to remove engine, split the cases and start your inspection. I wouldn't order any parts until complete dis-assembly and inspection. Several members have had Robinson's do the gear work, you can use this search process on this forum to find many articles and recommendations. I'm sure you will get many replies from members who have repaired their transmissions. At least you and the bike didn't go down.
 
there is a like 60 foot snake like black line i left when it did lock up at about 60ish on the highway right before the exit for bowles on 470 that almost did, fvcking new tire too so thats fun, nice little flat spot, better than my gear i know but FFS!
 
After looking at other people's carnage on this. Definitely 4th gear exploded. I guess I'm lucky the block does not have a hole in it! Makes sense. The hardcore sounds were if I took it from 5th to what used to be 4th.
I can't find much info other than Robertsons and the back cutting and 4th gear upgrade. Is that it? Are there better forks? Better rings?why does the forks wear down so fast? Would oil changes more frequently help this from happening so soon?
 
jmo
i think that the fork gets bent and causes it to pop out of 2nd.
a snap ring gets pushed out of its position (because of grove being to shallow) and then you get the gears grinding against the other gears breaking teeth or locking up the transmission.
 
Exactly my thoughts as well.
This is going to definitely be my next video series. I'm thinking in just going to do the carpenter 240 kit diy while I have it open. I know enough to know what I can do and when and why to have a proper machine shop do some of the work.
 
Some of the transmissions were assembled wrong with snap ring put in backwards at the factory. Robinson's will cut shaft deeper and wider to take bigger snap ring. Saw an article where some were converting to Spiralock's, which is probably a better retainer. Truth be told, if assembling snap ring correctly probably would be fine. Snap ring has a straight side and a rounding side. When I did my engine, I replaced several bearings, spacers, a gear and synro. and all snap rings, haven't had a problem, but if I did it again, I would have upgrade done, or at a minimum go to Spiralock's.
 
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Don't think changing the oil more often would change forks being bent, too much pressure from foot is problem with forks in my opinion. Just think how much pressure you can exert with your foot, shifting up and down. Use a good oil/filter and regular changes is always good medicine
 
Heel shifting also suspect!
 
I've seen dirt bikes with tiny little forks last a lot longer. Of you have ever been sort off road riding you would know how hard that shifter takes a beating. Yet all my motorcycles and off road equipment had 2 to 4 times the miles the rocket has or most even see. I have a hard time believing that just the force of the foot and leg casually riding would cause this much damage or bending. But idk. I always thought maybe mine was damaged when the po wretched it. It did fall on that side and may have slammed 2nd hard it did shear off the motor casting standoffs.