Motorcycle Repair: second gear noise

Question
by bike is a 1965 305 dream. and it has sat for about two years. it started right up. but when I let out on the clutch it jumps and dies. This has happened before and the last time this happened I put it in second gear and took off.but when I did the same this time it jumped and died. So I tried it in first and the bike took off. But when I shifted into second it made a noise like something had broke.I shifted it back into first and rode it backin the driveway. Put it on center stand started it up pulled in on the clutch and put it in first shifted it into second and had the same noise. do you think that second gear is broke if so is it hard to replace.

Answer
Tony, your primary problem is that the clutch plates are all stuck together, so even though you are pulling in the clutch, the plates are not releasing, so it is the same as if you weren't pulling the clutch lever in at all.

There is a TSB document covering Dreams which jump out of second gear, which is solved with some offset gear cotters, but the engine has to come out and the cases split to do the repairs.

You might want to check out how much chain slack you have, assuming that the chain guard is still in place. When you bang the transmission into gear it causes a shock through the whole drivetrain, from the transmission to clutch to drive chain and onto the rear drive cushions.

The sound you are most likely hearing is just the gears banging into each other under power. If it is done frequently or hard enough just once, it can shear the gear dogs off the end of the transmission gears or break the gear completely.

Drain the oil, remove the left side exhaust system, then pull the clutch cover and pry the clutch plates apart. Sand/wire brush the steel plates and inspect the friction discs to see if they are worn excessively. If the inner/outer clutch hub splines are notched, they should be smoothed out or just replace the worn parts.

I have a comprehensive Restoration Guide CD/Download available that will print out about 2,000 pages, if you need further detailed assistance.

Bill Silver
www.vintagehonda.com