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Post  RugbyCat on Sun Aug 14 2011, 22:33

Hello all. I've had my 'Cat for over 11 years and recently started having what i now know is the common jumping 2nd gear problem. Well as the only recommended cost effective cure was a second hand engine, therefore mine had to come out anyway - plus i'm a design engineer (but yes i can do practical too!) - well it would have been rude not to give it a go myself. Well guess what - i've only gone and done it! First ride out last night after engine and transmission strip down and rebuild went perfectly. So where better to share it than on a site dedicated to the bike itself.
I've never had any other problems with my 'Cat and now feel slightly more attached to it after all the hours of hard work i've lavished on it so can't see me changing it any time soon.
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Post  Rosco on Sun Aug 14 2011, 22:50

Hi Rugbycat

That is great news...a job well done.
Welcome to the site and thanks for sharing a good news (in the end) story.

Cheers
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Post  robertcains on Sun Aug 14 2011, 23:01

Respect, hope u have many more years out of your cat, You & Radar will be counting the time of ownership down to the minutes when he reads this post old
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Post  Panzerbuilder on Sun Aug 14 2011, 23:07

Hello RC and well done witha major strip down and repair.

My hat is off to you.

Also I assume its union and not league (rugby) that is. Smile
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Post  ellie on Mon Aug 15 2011, 07:24

Welcome to the gang, respect to you for the re-build! great




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Post  0ldcat on Mon Aug 15 2011, 09:03

Welcome RugbyCat,

Good news indeedy, and respect for the strip down,clean,repair and re-assemble great

See you out there sometime maybe.

clink
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Post  SteveCat on Mon Aug 15 2011, 09:08

Hi, welcome and well done on the gearbox repair
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Post  YZFJohn on Mon Aug 15 2011, 09:56

Welcome - respect, sorry to say for me that would have been a repair shop job!
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Post  RugbyCat on Mon Aug 15 2011, 10:12

Thanks all for the welcome - and the praise. Have to say though that i enjoyed all the work. Like a big 3D jigsaw that was fairly easy with the help of a trusty Haynes manual.
The Rugby by the way is in reference to the town i live in as opposed to the game that it gave it's name too - but it would be union rather than league. No offence.
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Post  yamahamad on Mon Aug 15 2011, 11:49

Hi & welcome. Well done on the rebuild. How many miles on the bike when the 2nd gear issue started?

Paul.
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Post  Guest on Mon Aug 15 2011, 19:26

@yamahamad wrote:Hi & welcome. Well done on the rebuild. How many miles on the bike when the 2nd gear issue started?

Paul.

That's a good question , as am I right in thinking that most owners in here haven't experienced the "2nd gear" problem ?
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Post  RugbyCat on Mon Aug 15 2011, 21:32

Bikes done just under 32K miles. Must admit to it being a bit of a fair weather toy but do erm ..... make progress shall we say. But not overly so, so it's not like it's had too hard a life and only a few track days. And haven't averaged a high milage in the time i've had it due to getting time on it with a young family.

Problem starts with the bike not always going into 2nd gear on the first attempt regularly then, as it gets worse, it'll start to 'jump' out of 2nd at about 5-6000 revs - as you try and get more power through it. Short shifting into 3rd gets round the problem for a short time and then all the other gears are fine. Its the lugs on the sliding gear, that interface with the 2nd gear pinion, rounding themselves off. The jumping also damages the mating selector fork so i had to replace these 3 components. plus i replaced all the gaskets, o rings etc. Local bike garage wouldn't even quote for the work as there were too many hours labour involved to make it cost effective.

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Post  greencat on Tue Aug 16 2011, 08:56

Hi RugbyCat,

Welcome to the site. I'd like to add my congratulations on a job well done. I've tinkered in the past but have never done anything as serious as that! Well done.

Hope you're enjoying the site. You should try and join one of our events so we can marvel at 'Rebuilt thundercat' Very Happy Hope she provides you with many more years enjoyment. great Errr...umph, the bike I mean, of course Embarassed

Chris

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I'm not just a 'cat, I'm an IAMs  'cat.  Where better to share this! Iam_mc10
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Post  t-catChris on Tue Aug 16 2011, 13:53

@RugbyCat wrote:
Problem starts with the bike not always going into 2nd gear on the first attempt

OH bugger......mine does this! :(
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Post  0ldcat on Tue Aug 16 2011, 16:06

@t-catChris wrote:
@RugbyCat wrote:
Problem starts with the bike not always going into 2nd gear on the first attempt

OH bugger......mine does this! :(
@SteveCat wrote: Maybe we should split the thread at this point ...
{ Done & Continued HERE ~ Admin great ~}
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