So a bit of an update, reposted from another thread....
During second practice; entering T3 I took a downshift and heard some chatter from the transmission as the gear wouldn't engage. I tried to up shift still nothing, so a bailed into the T3-T10 split ending my practice. I had had this issue once last season enter in the bowl, thought it was user error. It occurred once round 1 then again round 3 and now, always on downshifts. I had installed a shift star prior to this round hoping it would rectify the issue, but apparently not......................
So I rip into it; as he stood by talking with some other riders while. Within an hour of work I was able to strip it down and pull the shift forks out to find this...
Left to right 5/6 - 3/1 - 2/4
You can clearly see each one of the ears are worn especially on the 1/2nd's each one's thickness was only ~.05 above factory tolerable specs to be replaced. Also you can tell from the radius shaped wear at the bottom of the 3/1 and slightly on the 2/4 that they are bent as well. The shift drum has no signs of wear and is well within spec. I still need to verify that the gear groves are within spec and the dogs /slots appear okay later today, knock on wood they are. Hopefully it’s just the shift forks themselves, which are already on order ($160).
Well add one more thing to the list, shift drum assembly
Yesterday evening after work I put the bike back on its side in an attempt to inspect the Dogs / slots. While doing to I noticed some lateral movement from the 3rd and 4th. I decide enough was enough, packed up my trailer and went back to CT for the night (no garage here
1.5hr after I get home...
And the cases are split!
Cardboard is our friend
Pics of the gears / slots. You can see the wear, and the slight rounding on the edged of the dogs
1st has very light wear and second is just like 3rd and 4th
Got the new gears / dogs in.... Good vs Bad
Right now Im in the hole ~$600. Hopefully when I get home Friday night I can put the bottom end back together and get the valve lashing done in the AM so I'll have time to swap out shims with a dealer. Then Sunday have it back in and running, fingers crossed.
Im still in the hunt for a thinner head gasket, there used to be OEM KIT ones however with a 10yr old bike those parts are now basicly non existant. Cometic only has a .45 which is -.40. I think that might be way to thin i.e. valve clearance issues and to high of a compression. So I might be beat with doing that
Edit: with little time left and coming up short on my searches, I ordered a Comitec .45 gasket