1985 GS550E jumps out of gear???

[1978GS750E]

I have a 1985 GS550E that I am attempting to get in running condition again after sitting for a couple of years. It will jump out of 3rd and 4th gear occasionally when under hard throttle. I have adjusted the clutch per the service manual, it has new Rotella T4 oil in it, and it shifts smoothly up but has issues when downshifting (hard to find the gears). I have only ridden the bike for about 15 miles since I got the carbs sorted. I don't think this is something that more miles will help cure???

Anyone have anything else to check before I pull the engine and replace the gearbox? (I have a spare engine)

And I thought these $%^&* carbs were difficult! GEEZ

[rphillips]

My opinion, bad shift forks or worn dogs on gears, probably not gonn'a fix itself. You've got to split the cases to fix the trans, If your spare eng. is OK it'd be easier to just put your sorted carbs on that eng. & use it....Good luck.

[Baatfam]

My opinion, bad shift forks or worn dogs on gears, probably not gonn'a fix itself. You've got to split the cases to fix the trans, If your spare eng. is OK it'd be easier to just put your sorted carbs on that eng. & use it....Good luck.

This right here.
On my 1100 it was the 2nd gear dogs that were worn, but I replaced the shift forks also whilst it was opened up.

[1978GS750E]

My opinion, bad shift forks or worn dogs on gears, probably not gonn'a fix itself. You've got to split the cases to fix the trans, If your spare eng. is OK it'd be easier to just put your sorted carbs on that eng. & use it....Good luck.

Thanks for the replies. I was thinking the shift forks or dogs were bad. This thing must have seen some real abuse in its' former life! Going to have to pull the engine anyway, so will probably split the cases and rob parts from the spare engine, since I know that the current engine runs good and only has 15K miles on it. The spare is of unknown mileage and condition so I'll split that case first and see what that tranny looks like.

I just love bringing these old bikes back from the dead!

[Grimly]

This is usually the long-term effect of a PO who was in the habit of clutchless shifting, curse them.

[timebombprod]

mine pops out of second sometimes, im gonna have to check my gears while the engine is open, after a quick inspection i wasnt able to see anything worn or damaged, so what should i be looking for as a sign of wear?

[Grimly]

Look here...

http://www.aperaceparts.com/transmissions.html

[Carter Turk]

It's probably worse than this, but a friend had an 83 750ES with similar issues popping out of gear.

It ended up being this part (#21) on an OEM diagram, accessible from the oil pan cover w/o splitting cases.

Something referred to like a gear drum detent spring, that hooks to the webbing on the engine case,


SPRING
09443-08032

[1978GS750E]

No more calls.....We have a winner!

Yanked the exhaust off, drained the oil and found a very strange looking curved piece of wire stuck to the drain plug???? Dropped the oil pan and found this:



Now off to buy lottery tickets!

Thanks for the heads up there Carter Turk!

[rphillips]

Weeeuuuu 1978, Congrats to you. & a big Thanks to Carter, seem you've taught a few of something to be aware of...Dang I like this place.