Broken Shift Drum

[chasemotox63]

Hey guys, yesterday while I was racing my bike wouldn't shift into second gear. I suspected a bent shift fork, but I got the cases split for the first time (never done it before) and I found some metal chunks and a broken shift drum. Just thought I'd share some pics.

Any ideas on how to get the shift drum out???

Also, what could've caused this?

Thanks in advance guys!

[asg5265]

it "JUST" presses out. Now this might be different than a 89 2t I did once, but generally they all just kinda sit in there. you might take the thing over to a shop and ask them how they do it.

[asg5265]

what causes this? stressing the tranny after a blown shift.

[SunSeaSnow82]

When you have removed all associated bolts it comes out by hand. My 09 did anyway.

[asg5265]

I dont know if there is a keeper tab that is screwed in or what but I could only imagine there would be.

[garydnc]

Once you remove the bolt that holds it in, it will come off.

[chasemotox63]

Thanks for the info guys! If the parts get here by wednesday hopefully i will have it back together by Saturday.

[MrBlahh]

ouch, does he clutch with every shift ? or only when taking off from a stop

[chasemotox63]

I use the clutch for shifting both up and down, I have no idea how this happened.

[asg5265]

do you blow shifts every once in a while, or even regularly?

[chasemotox63]

Well sometimes off the start I will shift from 2nd to 3rd while pulling in the clutch, but I don't shut off the throttle. I'm not exactly sure what it means to "blow a shift" I guess.

[asg5265]

missing a gear then just putting the bike right back in gear and not letting the motor slow down.

[chasemotox63]

I think I've maybe done that 3 times on accident, but I don't recall doing it during the race

[asg5265]

hmm, well then maybe you just got one that was too hard. It actually happens and finally after so many heat and cooling cycles the next time you wanted to do shift it finally just said eff it, im puttin the gloves in. that would be my first though considering its steel.

[chasemotox63]

Got the drum out and the parts are scheduled to be here tomorrow. Planning to race on Saturday, so hopefully my first reassembly of a motor goes well!

Should I just use a rag and some compressed air to clean the metal filings out of the cases?

[asg5265]

and some brake cleaner! get at least two cans worth!

[chasemotox63]

Motor is back in the frame and now I'm just trying to get the thing in time. I thought I had it right, but when I put the tensioner in, it looks like I am one tooth off on both. I should probably adjust the marks based on when the tensioner is in, right? Because I think there is enough play in the chain and cams when there are loose that I can make it look right when it isnt.

[asg5265]

yeah you need to check it after you put the tensioner in. its a B to get right.

[chasemotox63]

Thanks, I'll move them both one tooth and hope it's right after I put the tensioner in.

[asg5265]

also, if it looks slightly off without it just remember that if the gear is off one tooth it will be very evident not like you need to get super anal about it being absolutely dead on. They either line up or they dont.