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  #1  
Old 15th October 2018
sltm1 sltm1 is offline
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Default Occasionally pops out of 2nd

I've been researching this problem here and other sites and plan to remedy it over the winter and I have no idea what the actual mileage is or what the PO's might have done. Dog's and shifter forks have been mentioned, but I just heard about another situation where this would happen, a worn clutch spring plate....any thoughts on testing that before tearing into the tranny? BTW, when it pops out the engine rev's for a second or two, then it re-engages. Last thought, could it be I'm not aggressive enough with my foot when shifting?
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Old 15th October 2018
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I’m doubting the “worn clutch spring plate” theory. Better to first check out the shifter mechanism from the outside in, starting at the lever - make sure it can move through the full range of motion.
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Old 16th October 2018
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Most likely worn dogs. My old transmission did it due to years of neglect and half ass shifts before I got it. Can't hurt to check everything else before you get in to the transmission.
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Old 17th October 2018
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No, don't be over aggressive you your foot when changing gears.

Most likely dogs are chipped/worn. You will never really know until the box comes out.
The fact that it drops back into gear tells me the detent spring is working OK.
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Old 18th October 2018
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Quote:
Originally Posted by sltm1 View Post
Last thought, could it be I'm not aggressive enough with my foot when shifting?
Not in the least.

About 95% of motorbike riders are never, ever taught how to shift properly. Instead, they lay on the foot change like maniacs. More damage from "hard" shifting and those riders that insist on wearing big clunky boots.

Put those same riders on a foot clutch bike where they actually "feel" each shift in their hand -- and suddenly your whole relationship with transmissions change.

In this case, you're taking the transmission out, checking everything thing, and fixing what's wrong.

When done correctly, a very minute push on the lever and a coordinate use of the throttle will see you neatly and beautifully snick into every gear.

The ironhead has one of the best feeling transmissions around. But, it needs care and attention to achieve the buttery feel.

We're here to help you figure it out -- if you want to take on the challenge
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Old 18th October 2018
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I had the same problem on my '78 and discovered a worn shifter fork, incorrect gaps and a slightly worn cam plate when I disassembled the trans. Replacing the worn parts and dialing in all the clearances to be spot on cleared the problem.

Here's a short video showing the problem with my trans.
https://youtu.be/PAVp5QPyiAk

Eric
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