6th gear failure

Has anyone else had 6th gear want to keep jumping out?

I've just finished repairing my gearbox and I know of at least one other case of this happening.

 

I recall a post from a member in Africa where his 1200’s engine gave up the ghost really early. Turned out a bunch of swarf was circulating in his engine, which eventually caused it to fail. I believe Honda eventually owned up to it but it was an uphill battle if I recall the whole story correctly. Perhaps his issue is akin to yours, just poor tolerance parts being installed?

 

I do not have a thorough understanding of everything that goes on in a transmission. What was the cause and what had to be repaired/replaced?

 

Could part of the problem been lightly resting your foot against the shift lever? That would cause the shifing
fork to be in constant contact with the gears rather than floating as it should.

This is something that I've never actually heard of so just guessing at the cause. Something has caused the
shifting fork to be in constant contact with the gear causing problems.

 

The gear trying to separate was causing it to push against the shift fork.
Do you have an understanding of how the shift drum works?
Resting your foot on the shifter does not apply pressure to the fork as the slot is straight once it goes into 6th.
And....I always ride on the balls of my feet.

 

Yes, I understand how they work, and if you raise/lower the shift lever it can move in the slot of the shifting
drum to the point where it tries to move the shift fork. Some slots in the drum are simply V-shaped where
as soon as the drum is turned the fork has pressure to move.

Why was the gear trying to separate? There shouldn't be any side thrust to speak of. Not like they're helical
cut gears.

Just looking at the photos again, it almost looks like the shift fork was riding on the gear dogs, that can't be.