Every once in a while, while I'm really letting it rip in second gear, it pops out of gear. I can shift back into it again right away but it is a little unnerving. Is it a sign of clutch wear? I ride a '78 650b
Sounds like second gear might need to be back cut or replaced. These are known for this, mine did it so bad shifting from 1st to sec on a wheelie, it would jerk back and forth rapidly. I back cut my own but wouldn't reccommend it. Always check the forks while it's apart. I couldn't use second gear on mine it got so bad.
Your about to get very well acquainted with your bike.
You need to split the cases to change either second gear or the whole transmission.
Second gear is the weak link in almost every make of motorcycle.
I had that problem before with my 78 KZ1000 and had to split the cases.
When I did I found that the circlip had came off the shift rod because the groove was not cut deep enough.
An easy fix once I got to it.
Same symptoms, the bike would would still shift, but it would pop out when I was getting on it.
If this is the problem you will see it right away and it is just a matter of cutting a deeper groove and using a fresh circlip.
I am lucky to know a good machinist.
You don't have to pull out the gear cluster or anything real tricky.
And if somebody says you should dress up the first gear while you have it that far apart and he'll do it for cheap
"Don't do it", but thats a story for some other time.
Good luck JD
normally if a transmission is popping out of gear it means the shift dogs on that gear are worn out it most likley means second gear on both shafts will have to be replaced or at the very least if they aren't to badly chewed up undercut
1973 z1 2-1974z1-a,2-1975z1-b dragbikes1015cc+1393cc, 1977kz1000,1978kz1000,1981kz1000j, 1997 zx-11, 2000 z12r,1428turbo nitrous pro-mod and a shit load of parts thats all for now leader sask.,CANADA
I THINK MY POWERBAND BROKE
It's got about 24k miles. Today it did it again right as i was about to shift at 8 grand and the motor wound up to maybe 11k rpm. My buddy behind me said that black smoke came out the exhaust right then.
24,000 miles it's still a pup.
I can't believe the gears or shift forks are trashed all ready.
I'd put my money on the circlip coming off.
On my bike the shift rod had fell out of position but still shifted, but when I'd hammer 2nd it would pop out of gear
I think I had about that many miles on my 78 kz1000 at the time.
I wonder if the shift rods are the same type, from a bad batch.
What ever the problem is, I recommend you pull the motor and split the case and have a look before it screws something else up.
It isn't that bad to do I think I took it out one night and put it back together the next( I had a buddy help me) and hopefully all you'll need is that groove cut deeper and a new gasket.
Good luck and keep us posted. JD
it could be a combo of the forks and the dogs, Oh and lets not forget the circlip.
any ways.u may be able to pull the pan and have a look see. u can pull the fork rod out and inspect it's groove, and the forks without pulling the motor.
u should be able to see enough of the dogs on the 2nd gears, from underneeth, to tell how bad they are.
if bad u should be able to find a good used trany cheap.
01 CBR600F4i Track bike.