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Thanks again zed, I am going to go with an mls gasket. I appreciate the advice this should be a wicked machine when done

Going to send out my transmission tomorrow to get back cut. Is a billet second gear worth it? Thanks 

Yes, worth it, better now than later.  Old thread that might help.... kzrider.com/forum/2-engine/612067-2nd-ge...ese-be-saved?start=0

turbodarnell wrote:

Going to send out my transmission tomorrow to get back cut. Is a billet second gear worth it? Thanks 

Yes! It's essential.
2nd gear is the weak link even in the stock motor especially if it's been hammered on or wheelied regular etc.
Because of the gears small diameter there's one particular area where there's very little material between the root of one of the gear teeth and the internal spline and with the stock gears being cast steel they are prone to fracture.
This causes the gear to pop open and split in two with nasty consequences.
Even at low speed it can cause the gearbox to lock and split the top crankcase in half from left to right behind the oil pressure switch.
This happened recently to a friends 1000a as he was on the slip road to the motorway doing around 40 mph.. 




 

ok i will pick up a billet second, thanks ! hopefully this motor will be bullet proof. welded crank, backcut trans, all heavy duty cylinder and main bearing studs, main bearing support plate, oil pan gate, j head, forged pistons, mls head gasket. i hope it will survive 30 psi if i want to push it there! 

Also interesting on why billet anything ...  www.superatv.com/offroad-atlas/truth-about-billet/

Billet steels grain structure is a bit stronger than cast, not quite as strong as forged but material is definitely of higher quality. Second gear inputs as stated by zed wear out and break prematurely- better be safe than sorry considering the amount of money spent on the engine 

Thank's for the additional info Fella's. Just purchased a Gear-set from MRE, Jay was soo personable.Not to be confused with the Jay from APE. But ain't as cheap as You fellas remember, Just shy of 700USD.so added a 122 camchain that is NOT a split roller 122. 2ND gear set is what Orient Express uses and the usual undercut. It's just money ya know.

Just for reference, gearsets just arrived. These are the costs these days. Albeit i did purchase a 122 camchain, so take that off the price of course. Offered a core but they were't really interested. Just Info.

don't forget the clutch basket.
 

But of course!

How thick is a compressed mls gasket typically? I assume 0.2” like base gasket. Thank u!!