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Honda Nighthawk 700s Transmission broken shift fork

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


 


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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 driven gear. 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.





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Motorcycle Bottom End Rebuild Part 3 (of 3) Final Assembly
https://www.rockymountainatvmc.com/t/731/Shop-Tools?utm_source=Youtube&utm_ 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 @ www.rockymountainatvmc.com! Click Here For Part 1 (Flywheel, Stator & Clutch Removal) https://www.youtube.com/watch?v=kYX-bOG9vR4 Click Here For Part 2 (Splitting Cases, Crank & Transmission Removal, Crank & Bearing Installation) https://www.youtube.com/watch?v=vVKeT8Mh2dQ Click Here To Subscribe To Our Channel! http://www.youtube.com/channel/UCQSXoYEPBXNPSx1hWbO2WRQ?sub_confirmation=1 See All Tools And Accessories Here! https://www.rockymountainatvmc.com/t/1655/Shop-Tools?utm_source=Youtube&utm _medium=BottomEndRebuild1of3&utm_campaign=Youtubevideos





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Honda Nighthawk 700s new engine start up
Honda Nighthawk 700s new engine start up. Getting a few noises but otherwise looks good, still need to sync the carbs and fix an oil drip.





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.





Honda Nighthawk 700s transmission
Finished the teardown of the spare engine on the Honda Nighthawk 700s. I need the shift forks for the other engine.





Oh shift forks!





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