Tight Transmission

[LOUD MOUSE]

The shaft looks perfect so here goes.
I'd like to recommend you assemble the trans again and make sure you can shift it as you turn the output shaft and the shift drum. I was able to get a trans together with the two slider gears reversed. A question I have is have you X'ed the two loose gears and the two removeable ones on the shafts? Are you making sure the 14mm brass bushing is installed with the correct end on the shaft first? ............lm

They are the same part. Honda superceded the numbers. Did the bad one have a groove where the 1/4 inch rollers contact the shaft?. .......lm

The shaft looked allright in that area; can't feel a groove, just some slight discoloration. Thanks for the p/n info, LM. Should I worry about a bit of runout on the mainshaft?
Or just replace the countershaft and check for binding?

Also I think I'll try to straighten this one out. If I mess it up even more, oh well!

[cfloren]

The shaft looks perfect so here goes.
I'd like to recommend you assemble the trans again and make sure you can shift it as you turn the output shaft and the shift drum. I was able to get a trans together with the two slider gears reversed. A question I have is have you X'ed the two loose gears and the two removeable ones on the shafts? Are you making sure the 14mm brass bushing is installed with the correct end on the shaft first? ............lm

Yes, I have X'ed the gears. In fact, I swapped them over and realized they were in the stock configuration, so I swapped back...apparently someone had X'ed them already. So, it was running in its current configuration before I tore it down. The brass bushing had an oil hole in one end; I matched that up with the hole on the shaft, near the counterweight. I double checked the gear setup by counting teeth before I tore it down again, and everything looked fine. Again, it shifted through all the gears with no problem, but it would get tight once per revolution and then loosen up again as I continued turning. To me, the bent countershaft is a logical culprit. I forgot to mention that the shaft is visibly bent. Laying it in the top case w/ bushings and turning, you can see the bend quite clearly.

[LOUD MOUSE]

I've got a problem with the gets tight as you turn it because that shaft doesn't turn.
Only the gears and main shaft do. Does the problem happen when in neutral?
That bushing has a tapered inside on one end. That goes on first. ...........lm

The shaft looks perfect so here goes.
I'd like to recommend you assemble the trans again and make sure you can shift it as you turn the output shaft and the shift drum. I was able to get a trans together with the two slider gears reversed. A question I have is have you X'ed the two loose gears and the two removeable ones on the shafts? Are you making sure the 14mm brass bushing is installed with the correct end on the shaft first? ............lm

Yes, I have X'ed the gears. In fact, I swapped them over and realized they were in the stock configuration, so I swapped back...apparently someone had X'ed them already. So, it was running in its current configuration before I tore it down. The brass bushing had an oil hole in one end; I matched that up with the hole on the shaft, near the counterweight. I double checked the gear setup by counting teeth before I tore it down again, and everything looked fine. Again, it shifted through all the gears with no problem, but it would get tight once per revolution and then loosen up again as I continued turning. To me, the bent countershaft is a logical culprit. I forgot to mention that the shaft is visibly bent. Laying it in the top case w/ bushings and turning, you can see the bend quite clearly.

[cfloren]

It's been a few days since I worked on the motor...
but yes the bushing was installed correctly.
And it doesn't bind up at all in neutral, although you can still barely feel more resistance in one spot.
I did swap in my less-bent kickshaft, and it seemed to make the problem better, but it still happens.
By the way, thanks a lot for the help so far LM.

[davomoto]

I too had the exact same problem. I changed the kick shaft, and it got a little better, but wouldn't shift properly. It turned out that I had the gear on the countershaft that the shift fork slides into on backwards. Her's some pics of how the tranny should look when properly assembled. Hope this helps, or perhaps you've already soved the problem?

[cfloren]

Well this is a really old thread, and it's "my bad" for never following up and sharing my solution to the problem. This tight transmission issue was plaguing me 2 1/2 years ago as I was assembling my bottom end.

I tried all of LM's suggestions and after scratching my head when the problem wouldn't go away, decided to inspect the mainshaft and kick spindle shaft for radial runout (i.e. bending). I didn't record the runout values, but they were obviously knackered.

I ordered an NOS mainshaft and kick spindle shaft, reassembled the trans, buttoned up the cases and boom! Problem solved.

-Chris

[greg78gs750]

this is an old thread, but i wanna say thank you! i was reassembling my transmission and COULD NOT get the gears to shift right. found this thread and found i had a gear in backwards. all is now well! thanks for posting the photos, guys!!

incidentally, either i had a lot of trouble interpreting it, or my parts diagram showing the transmission is wrong! it has the 3rd gear on the main shaft facing the wrong way!

thanks again davomoto!!!

greg