jumps out of gear

[cus]

G'day Everyone,
Took the 63 for a good test ride this weekend, timed it at 32 deg.,
& took off into the hills. The bike ran really well until I loaded it up
in 3rd, & it popped out. Went back & fiddled around with the
locator plunger, but made no difference, pretty sure its worn
dogs on third, but open to any other reasons before I strip the
box down. Other question is, if I have to get the dogs re-cut,
will I have to take off the inner primary etc., or can it all be
done from the kickstart side, & leave the main shaft in the box,
haven't had alot of experience with gearboxes, so any advise
appreciated. I have a good machinest/ mechanic that can do
the repair but I want to do all the strip down etc.

regards, Cus

[Goldy]

I would look at the selector fork first, make sure it,s in good condition not worn and moves freely and that the spring returns it correctly and that the spindle is not binding. All the best.

[muskrat]

Also check the forks have engaged both gears. It can happen that one jumps out as you assemble. I KNOW!!
Cheers

[cus]

Will I have to remove the clutch etc. to pull the guts out,
or can the main shaft stay in,

regards, Cus

[muskrat]

I'm not 100% sure but I think it can all come out without the mainshaft. You will need to remove the selector fork shaft.
Cheers

[trevinoz]

Cus,
          Does it select and stay in 4th?
How are the other gears?
Have a good look at the dogs and the camplate also.
Went to Nabiac swap on Sunday and a bloke had clusters for $80. They didn't last long!
  Trev.

[cus]

G'day Trevor,
All the other gears select & stay in fine,
3rd also selects well, but pops out under load,

Cus

[cus]

G'day Everyone,
Well, started dismantling the g/box, have outer & inner covers off,
is there a trick to removing the grub screw on the selector shaft
or is the only way to remove both primary cases to gain access,

regards, Cus

[cus]

Looks like no magic tool to take out the grub screw with primary cases on,
so it all came off, 1st & 3rd gear lock into each other & both are worn,
was able to get both NOS & going back together now, hopefully allsorted,

regards, cus

[t20racerman]

Looks like no magic tool to take out the grub screw with primary cases on,
so it all came off, 1st & 3rd gear lock into each other & both are worn,
was able to get both NOS & going back together now, hopefully allsorted,

regards, cus

Keep us posted. Mine jumps out of second under load at highish revs when giving it a handful (ie overtaking cars...) and it is a real pain in the ***. If you successfully fix yours it will motivate me to do mine! 

[wilko]

No wonder, if that's you doing a wheel stand in your avatar!!

[cus]

Yep, all sorted....for now!

Cus