Popping out of top gear - Honda RC51 Forum : RC51 Motorcycle Forums
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post #1 of 12 (permalink) Old 10-28-2012, 05:54 PM Thread Starter
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Popping out of top gear

I purchased a used 04 RC last spring and took it to the track. Everything ran great except it would pop out of top gear from time to time. The engine would rev to the max each time since I would always be pulling full throttle. The previous owner install a Star shift kit and never experienced this. I suspect he never really gave the engine a good go in top gear! Can Star Shift Kit be the cause of the gear box popping out of gear?
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post #2 of 12 (permalink) Old 10-28-2012, 06:07 PM
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Nope...in my experience and I've built lots of motors and transmissions. Only one cause for gears jumping out under load is worn engagement dogs on the drive gear of the input shaft and/or worn engagement holes in the driven gears on the output shaft.

The ONLY real fix is to replace the two gears, drive and driven. If you can do the work yourself 80% of the cost is labour. I've split lots of engine cases and if the RC is like most V-twins then unfortunately the top end has become off too.

I've done inline's where you can just flip the motor over remove the bottom case half and re-re the tranny...but in the case of the RC I think not.

Maybe Makis or b.miller could chime in if I'm mistaken about the RC, I don't think it is a cassette type transmission would be nice though.



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post #3 of 12 (permalink) Old 10-28-2012, 06:19 PM
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Nope...in my experience and I've built lots of motors and transmissions. Only one cause for gears jumping out under load is worn engagement dogs on the drive gear of the input shaft and/or worn engagement holes in the driven gears on the output shaft.

The ONLY real fix is to replace the two gears, drive and driven. If you can do the work yourself 80% of the cost is labour. I've split lots of engine cases and if the RC is like most V-twins then unfortunately the top end has become off too.

I've done inline's where you can just flip the motor over remove the bottom case half and re-re the tranny...but in the case of the RC I think not.

Maybe Makis or b.miller could chime in if I'm mistaken about the RC, I don't think it is a cassette type transmission would be nice though.
+1000R

RC51 doesn't have a cassette type transmission gearbox. You'll have to split the cases eventually.



Like nobody said (darn that sounds chaotic ) it's 80% labor.
The shift drum's dogs are No1 suspects in this case.


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post #4 of 12 (permalink) Old 10-28-2012, 06:30 PM
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I've experienced this from time to time on various bikes. Check your shift linkage and make sure it is functioning properly and has a good solid throw through the lever action. Concentrate on making solid shifts. Switch to a VFR shifter for linkage free GP shifting!

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post #5 of 12 (permalink) Old 10-28-2012, 06:50 PM Thread Starter
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The bike came with a quick shifter. I tried shifting using the clutch and it would still pop out of gear from time to time.

Taking the engine out to split the case is indeed a lot of work. Even though I've never done a complete engine removal and tear down, I'm certainly capable. That would be a winter project for sure. If I recall, there are a number of special tools that would need to be made or purchased!
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post #6 of 12 (permalink) Old 10-28-2012, 07:52 PM
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Change the sprockets and don't use 6th gear, 17/36 should suffice

This is a good thread on engineer rebuilding: http://www.speedzilla.com/forums/hon...ild-101-a.html




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post #7 of 12 (permalink) Old 10-28-2012, 08:00 PM Thread Starter
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Change the sprockets and don't use 6th gear, 17/36 should suffice

This is a good thread on engineer rebuilding: http://www.speedzilla.com/forums/hon...ild-101-a.html
The track I ride has a very long straight that needs 6th gear otherwise it would not get used much. I will have a look at the rebuild thread should I decide to go that way.
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post #8 of 12 (permalink) Old 10-28-2012, 09:31 PM
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Try changing the shifter return spring. I have done this on several of my past rides and it helps. IMO, shift kits arent worth their money. (Maybe put new OEM parts in place of the shift kit...)



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post #9 of 12 (permalink) Old 10-29-2012, 07:51 PM Thread Starter
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Try changing the shifter return spring. I have done this on several of my past rides and it helps. IMO, shift kits arent worth their money. (Maybe put new OEM parts in place of the shift kit...)
What does the shift return spring do? I have the OEM parts and will likely put them back in or at the very least, make sure they are installed correctly. It's a whole lot simpler than splitting the engine. I have no idea how the whole shift kit interconnects with all the other parts. Maybe it has no influence on the popping out of gear issue what so ever!
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post #10 of 12 (permalink) Old 10-29-2012, 08:27 PM
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What does the shift return spring do? I have the OEM parts and will likely put them back in or at the very least, make sure they are installed correctly. It's a whole lot simpler than splitting the engine. I have no idea how the whole shift kit interconnects with all the other parts. Maybe it has no influence on the popping out of gear issue what so ever!
Honestly, the shift return spring should not affect the transmisson as in jumping out of gear.

It will be the suggestion that Makis made or myself...the only real way to know is to split the engine cases and inspect and measure compared to the manual.

But if you look at the 6th gear driven and drive gear most likely you will find the tell tale signs of wear.

Good luck and keep us posted.



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