This is one of the problems with the transmission. This is a shift fork from an 85 Honda Nighthawk 700s. The clutch had huge play in it and was slipping and grabbing, slipping and grabbing. Looks like this is the primary problem, but I'll have to install the new (used) forks and see if the play is gone. The spare engine has a MUCH tighter transmission
Honda Nighthawk 700s transmission: How It Works, shift drum
How a motorcycle shift drum works: The shift drum controls three shift
forks by a stub that rides in a slot. The slot moves the fork which moves
a slider gear. The slider gears has pegs that fall into holes in the
The slider gears engage on either side, 3 sliders X 2 sides = 6 gears.
Sometimes if your gears clash, the slots and dogs will round off, this can
cause the gear to pop out when you apply torque.
The drum is shifted with a ratchet system operated with your foot.
Suzuki GSX-R Transmission Install & crankcase assembly
Suzuki GSX-R Transmission Install & crankcase assembly. In order to get to
the gears the crankcase has to be deconstructed since it houses both the
engine & transmission. This video shows parts of the reconstruction
Honda CB450 shift problem diagnosis
This bike has the infamous 2nd shift problem
popping out of 2nd gear
not going into 2nd gear
Basically every part that could wear out....did.
2 of 3 shift forks
*Dad, i solved it, this will be a bad bike when its done. Thanks for the
Motorcycle Bottom End Rebuild Part 3 (of 3) Final Assembly
medium=BottomEndRebuild&utm_campaign=Youtubevideos - How-to disassemble and
rebuild the crankshaft and transmission on a modern 2-stroke motocross
motorcycle or ATV engine. This is Part 3 of this 3 part engine rebuild
series from Rocky Mountain ATV/MC. In this video we cover installing the
transmission into the case halve and then applying gasket maker onto the
sealing surfaces. Also installing the other case halve and sealing
everything up finishing the crank and bearing replacement on this engine.
Get all the parts and tools needed for this complete engine rebuild @
Click Here For Part 1 (Flywheel, Stator & Clutch Removal)
Click Here For Part 2 (Splitting Cases, Crank & Transmission Removal, Crank
& Bearing Installation)
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Honda Nighthawk 700s alt chain tensioner
Removing the alt/starter chain tension release rod. PITA to get to without
removing the alt, but I got it out. These release rods tend to brake and
take out the starter / alt chain with them. This doesn't effect the
tension on the chain, the rod is there to hold the tensioner in the
released position, you can do that with a screwdriver.
You have to split the cases to get access to this so I did this while
replacing a broken shift fork.