Well, the day started out $hitty

[Neville Lush]

what if your dogs hit the face of the spokes on the female gear?

Mate, this happens normally in virtually every bike gearbox. That is why the top corners of dogs eventually get rounded off. In an effort to make the gears in these bikes take load/torque, Triumph spin the box at near engine speed. The upshot of that is that there is less time for the dogs to engage as they whiz past their slots. Undercutting the gears will improve positive engagement but will also slightly enlarge the length of the dog windows allowing them to engage easier. If one is going to undercut the gears on a rocket, I would strongly suggest NOT using the angles one would use on a drag race engine/bike. Shim the box properly as well to remove slack so the gears cannot "get a run up" and smack into the next object( maybe a circlip) with as much impact. Having said all that I have done very few boxes here. I think whilst the spiralox clip seems like a good idea, it would be worse. I would rather have one thick rigid clip as it would seem to me that the two thin winds of clip will flex more in service. Machining the groove deeper will disturb the surface hardening of the shaft promoting a crack. Maybe look at various clips and see if a stiffer one can be found and install it correctly. If a lunatic like Ruzz can ride about with carefree abandon (gaily) with 240+ ft lbs of torque on the stock circlips and a friggin 8" car tyre they should be ok.

 

[sonny]

Mate, this happens normally in virtually every bike gearbox. That is why the top corners of dogs eventually get rounded off. In an effort to make the gears in these bikes take load/torque, Triumph spin the box at near engine speed. The upshot of that is that there is less time for the dogs to engage as they whiz past their slots. Undercutting the gears will improve positive engagement but will also slightly enlarge the length of the dog windows allowing them to engage easier. If one is going to undercut the gears on a rocket, I would strongly suggest NOT using the angles one would use on a drag race engine/bike. Shim the box properly as well to remove slack so the gears cannot "get a run up" and smack into the next object( maybe a circlip) with as much impact. Having said all that I have done very few boxes here. I think whilst the spiralox clip seems like a good idea, it would be worse. I would rather have one thick rigid clip as it would seem to me that the two thin winds of clip will flex more in service. Machining the groove deeper will disturb the surface hardening of the shaft promoting a crack. Maybe look at various clips and see if a stiffer one can be found and install it correctly. If a lunatic like Ruzz can ride about with carefree abandon (gaily) with 240+ ft lbs of torque on the stock circlips and a friggin 8" car tyre they should be ok.

Ok. My question to you is this. I have a 2015 Rocket X with 26,000 mile on her. Shifts really nice and have never had a problem. Do we have anything to worry about? Doing and planning on some expensive upgrades. Hate like #ell to think that the Transmission will give out like what we have read about. Is this a common problem or just folks posting that are not the majority. Thanks

 

[Neville Lush]

Are you worried about a tree falling on you when riding along?...... Seriously, if you have no sign of an issue there probably is none. I honestly believe the majority of these issues are due to sketchy assembly, bit like a KTM 85 crankshaft. If it feels ok it probably will be for years. This is only my belief I have no hard evidence to back it up. Put good oil in it, change it every 5000kms and ride the sucker.

 

[sonny]

Works for me. THANKS.

 

[Rocket Scientist]

Mate, this happens normally in virtually every bike gearbox. That is why the top corners of dogs eventually get rounded off. In an effort to make the gears in these bikes take load/torque, Triumph spin
the box at near engine speed. The upshot of that is that there is less time for the dogs to engage as they whiz past their slots. Undercutting the gears will improve positive engagement but will also slightly enlarge the length of the dog windows allowing them to engage easier. If one is going to undercut the gears on a rocket, I would strongly suggest NOT using the angles one would use on a drag race engine/bike. Shim the box properly as well to remove slack so the gears cannot "get a run up" and smack into the next object( maybe a circlip) with as much impact. Having said all that I have done very few boxes here. I think whilst the spiralox clip seems like a good idea, it would be worse. I would rather have one thick rigid clip as it would seem to me that the two thin winds of clip will flex more in service. Machining the groove deeper will disturb the surface hardening of the shaft promoting a crack. Maybe look at various clips and see if a stiffer one can be found and install it correctly. If a lunatic like Ruzz can ride about with carefree abandon (gaily) with 240+ ft lbs of torque on the stock circlips and a friggin 8" car tyre they should be ok.

There is a lot of metal yet on the splines before you get to the shaft proper, do you think cutting deeper into the splines but not all the way to
the bottom would still promote cracking ?

 

[Neville Lush]

Probably not on that picture. I was thinking the base shaft had the slot in it. Must be thinking of another part of the box. You will need some one with good tools/skill to do that .

 

[mr hunt]

Fred can you see any rounding of the groove edges on the shaft? I was satisfied that mine were still square so I didn't replace the shaft itself in my rebuild. The shafts are big $$ relative to the rest of the GB parts

 

[Rocket Scientist]

Fred can you see any rounding of the groove edges on the shaft? I was satisfied that mine were still square so I didn't replace the shaft itself in my rebuild. The shafts are big $$ relative to the rest of the GB parts

They look good with a magnifying glass. I haven't looked at them yet with a loupe. They still feel sharp.

Mate, this happens normally in virtually every bike gearbox. That is why the top corners of dogs eventually get rounded off. In an effort to make the gears in these bikes take load/torque, Triumph spin the box at near engine speed. The upshot of that is that there is less time for the dogs to engage as they whiz past their slots. Undercutting the gears will improve positive engagement but will also slightly enlarge the length of the dog windows allowing them to engage easier. If one is going to undercut the gears on a rocket, I would strongly suggest NOT using the angles one would use on a drag race engine/bike. Shim the box properly as well to remove slack so the gears cannot "get a run up" and smack into the next object( maybe a circlip) with as much impact. Having said all that I have done very few boxes here. I think whilst the spiralox clip seems like a good idea, it would be worse. I would rather have one thick rigid clip as it would seem to me that the two thin winds of clip will flex more in service. Machining the groove deeper will disturb the surface hardening of the shaft promoting a crack. Maybe look at various clips and see if a stiffer one can be found and install it correctly. If a lunatic like Ruzz can ride about with carefree abandon (gaily) with 240+ ft lbs of torque on the stock circlips and a friggin 8" car tyre they should be ok.

Would some place like Robinsons know the correct angle for a non-racing application ? As for shimming the play out of the gears, do you make your own shims ?

 

[Neville Lush]

I have said in other posts , yes we make our own shims. Talk to Robinson, tell him what you are doing and get his suggestions. If some one comes into my shop and says " you need to do it this way because I read it on a forum" it gets up my nose. I'm guessing he will be the same. Please note I am speaking in a polite, kind tone to you sir, not trying to annoy you, but trying to assist.

 

[Rocket Scientist]

I have said in other posts , yes we make our own shims. Talk to Robinson, tell him what you are doing and get his suggestions. If some one comes into my shop and says " you need to do it this way because I read it on a forum" it gets up my nose. I'm guessing he will be the same. Please note I am speaking in a polite, kind tone to you sir, not trying to annoy you, but trying to assist.

And I sir, value your opinion immensely and appreciate you taking the time to help me !