RF gearbox

[Drew]

Well, I bought my RF knowing it jumped out of second gear, and was de-regestered.

Spent a few hours the last 4 nights, splitting the crank case with officer Mikey. The selector fork for 2nd wasn't bent too bad, so I swapped it with the one for 5th because it only has to work one way.

Got it back in last night and the fuckin thing still jumps out of second, so I'm now on the hunt for a '86-'96 GSXR gear box, or bandit, or RF, since the good folk at Suzuki use the same bottom end for all.

On the plus side, whilst checking the mileage online, I discovered the registration had infact, not lapsed, so I/ve save a bucket load for the VIN I dont need.

[paturoa]

Do the dogs need to be re-ground? Prolly a much cheaper and easier solution.

[Colapop]

I'm still looking for a starter relay if you find a wrecked one...

[Drew]

Do the dogs need to be re-ground? Prolly a much cheaper and easier solution.

I know some engineers, more info please...


I'm still looking for a starter relay if you find a wrecked one...


Starter relay can come out of damn near anything Col, why you waiting?

[Scouse]

Why did you buy a RF then Drew? I thought a Gixxer or R1 or ZX10 or Blade would have been more your type of Machine

[Kickaha]

Got it back in last night and the fuckin thing still jumps out of second.

When does it do it? under load?

You might get away with undercutting the dogs, check them and see if they are rounded off

[Drew]

Why did you buy a RF then Drew? I thought a Gixxer or R1 or ZX10 or Blade would have been more your type of Machine

Those are definately more my cup of tea, but they cost lots, this didn't.

[Colapop]

You can still do lots on an RF... I seen ya on the Naked RiF Drew... Twas me in the Hilux at the lights...

[Drew]

You can still do lots on an RF... I seen ya on the Naked RiF Drew... Twas me in the Hilux at the lights...

That was my GIXXER bro.

[Colapop]

They ALL look like RF's to me!!

[paturoa]

I know some engineers, more info please...


As kickaha says above...

A common cause is the dogs on the gears get a rounded / taperred edge so that when the load comes on the dog pushes out of the slot and you get it jumping out of gear.

see here - but the zook ones normally have a flat face not like the pegs in the picture.

http://images.google.co.nz/imgres?imgurl=http://www.dansmc.com/dogs.jpg&imgrefurl=http://www.dansmc.com/gearbox.htm&usg=__M0xr9hiB9W-X2CdL_I1Aqu_xtkM=&h=442&w=570&sz=31&hl=en&start=57&tbnid=rAM37r4i-rvedM:&tbnh=104&tbnw=134&prev=/images%3Fq%3Dgearbox%2Bdogs%2Bsuzuki%26start%3D54% 26as_st%3Dy%26gbv%3D2%26ndsp%3D18%26hl%3Den%26sa%3 DN

What can be done reasonably easily with the right gear - phone around - is you mount the offending gear in a lathe chuck and a grinder in the post. Then the angle on the driving face of the dog gets reground.

Sometimes the angle is even cut negative rather than flat, but thats just silly.

The other option is that the slots that the dogs fit into are rounded off - much harder to machine these - I've seen a butcher job done years ago with a dremmel. Its often just as easy to get a new cog if that is the case.1

Here is a cog from the mighty SV. The arrow is pointing at the dog face.

[Drew]

As kickaha says above...

A common cause is the dogs on the gears get a rounded / taperred edge so that when the load comes on the dog pushes out of the slot and you get it jumping out of gear.

see here - but the zook ones normally have a flat face not like the pegs in the picture.

http://images.google.co.nz/imgres?imgurl=http://www.dansmc.com/dogs.jpg&imgrefurl=http://www.dansmc.com/gearbox.htm&usg=__M0xr9hiB9W-X2CdL_I1Aqu_xtkM=&h=442&w=570&sz=31&hl=en&start=57&tbnid=rAM37r4i-rvedM:&tbnh=104&tbnw=134&prev=/images%3Fq%3Dgearbox%2Bdogs%2Bsuzuki%26start%3D54% 26as_st%3Dy%26gbv%3D2%26ndsp%3D18%26hl%3Den%26sa%3 DN

What can be done reasonably easily with the right gear - phone around - is you mount the offending gear in a lathe chuck and a grinder in the post. Then the angle on the driving face of the dog gets reground.

Sometimes the angle is even cut negative rather than flat, but thats just silly.

The other option is that the slots that the dogs fit into are rounded off - much harder to machine these - I've seen a butcher job done years ago with a dremmel. Its often just as easy to get a new cog if that is the case.1

Here is a cog from the mighty SV. The arrow is pointing at the dog face.

Thanks for that, very helpfull.