83 interceptor 2nd gear problems

In this case yes it does. Some time ago in fact.

 

not good news for my '83

I'm hoping my bike doesn't have the same problem.
It has popped out of 2nd gear a couple of times under hard acceleration.
I just finished a full carb clean and rebuild.
Last year I replaced the entire exhaust.
Man, I don'f feel like tearing the bike apart again.
I was wondering if it is a clutch problem.

 

Sorry man, if it's popped out of gear like that then it's definitely "going". It won't heal itself, as long as you are careful and don't abuse it too much you should be able to prevent any further damage.

Tearing into it isn't the problem, it's getting the parts to fix it once it's apart.

 

ok after reuilding and buying a BRAND NEW SHIFT FORK put the whold thing back toghter. runs great except now it wont hold in second gear again. what else hold this in gear. kinda weird there is no way it took out that shift fork again. and yes they are still available. this whole bike has been rebuilt from the ground up and i cant get the mother to hold second.. wtf

 

You can't just replace the shift fork - you normally also have to replace the two mating gears and the shift drum. The shift fork is collateral damage and not the cause of the problem. Sorry man!

 

they seems to be in perfect condition with no wear. the frok and gear were replaced. does the star shaped thing on the side of the shift drum lock this in to gear.. if i slowly accelerate it works perfect if i go a little harcder it dumps into neutral. before it would grind and shake violently. what else couls it be

 

the cam drum and gear shift spindle do thes hold it in gear

 

If I remember correctly you can watch the 'action' of the transmission by removing the oil pan and shifting throught the gears while turning the countershaft. You might be able to get an idea as to what's happening. Refer to the shop manual and make double sure you have all shims and thrust washers in place. Check for excessive side play in the main and countershaft. Usually if there's a problem with the linkage (i.e. shift star) ALL the gears will malfunction. Other than not being assembled correctly, I don't think there's much else that can make a bike 'pop' out of just one gear aside from shift fork/worn gear dogs...maybe the shift drum but think that's unikely.

 

You have to look very closely at the shift drum right in the ramp to second gear. The damage is not some huge chunk or anything, it's pretty small. Also you have to look at the ends of the gear dogs. What might seem like good condition parts could really be junk if you look close enough. Obviously something is wrong. The shifter star is not likely, but the spring on the detent arm might be a source (I highly doubt it). Popping out of gear is caused by the gear dogs, shift drum, and shift fork. As mentioned, it normally requires replacing all three before the problem is corrected.

 

wow do u have a pic of what the dogs look like on second gear. cant belive there is no way to fix thes dogs. why cant u grind them flat? wouldnt that fix it?

 

Sorry, I only have pictures of what they look like after an undercut service. Undercutting the gearbox will repair the dogs and is really the only thing you can do besides finding some new parts (needle in a haystack!). Contact Dave Dodge, he's the one I've been using for the last few years for gearbox undercutting.

 

so grinding down the rounded parts flat woulnt work? and where under cuts this stuff at

 

what gears on this thig are usally the ones neede to be replaced for second gear.. part number would be great

 

Just e-mail Dave at drp123@mindspring.com . I wouldn't just grind down the gear dogs, I doubt that would work.

It's the gears that engage to lock in second gear. It's usually pretty easy - they are the part numbers that are discontinued!