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GS450 Catastrophic failure

Second transmission, and second transmission failure? It'll be interesting to find the culprit, though you may want to leave that to the next owner. Please keep us advised.
 
Haven't taken a look at the system physically. But I pondered through any recent changes I've made, and realized both transmission failures occurred after changing the clutch ramp.

A bit more than a month back, my chain skipped a tooth and shredded the little actuator shaft as well as the clutch actuator ramp; I recall reading somewhere on here that the GS500 had a nicer clutch ramp on account of not being made of a greased piece of plastic but instead a nice set of ball bearings on a metal ramp.

The GS500 ramp fit right into where the 450 assembly went, and after removing 95% of the play on the clutch rod adjustment, loved how much easier the clutch could be actuated.

Now I'm wondering... both failures seemed to happen while shifting from first to second. Broken circlip found the first time, haven't taken a look for the second. I wonder if the clutch didn't get fully disengaged and this caused tooth damage somehow? But that doesn't make sense, wouldn't it only chip the leading edge of one of the transmission dogs?

How could I examine the transmission while the engine is all together?

GS450 Ramp: s-l1600.jpg - Click image for larger version  Name:	s-l1600.jpg Views:	0 Size:	10.9 KB ID:	1728239


Replacement GS500 ramp:


Ramp 500-1
Ramp 500-2
 
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Engine out, upside down, drop the sump, you'll see most of the transmission. Again, check the endfloat on the shift drum.
 
Notches are probably identifiers for semi-skilled labour on the assembly line.
Before assembling the box, check the endfloat on the shift drum. If that is excessive it can put load on the circlips between gears. Should be only just discernable movement - about 003- .005 in.

I really wish I'd managed to read this before I had closed up the engine. Will do Greg, thanks.

Just to be sure (because it looks like no based on memory), there's no way to check that without at least taking off the clutch side of the engine housing right?
 
With the sump off from memory you can see the shift drum. Levering it side to side will give you an idea of how much endfloat it has.
 
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