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#710039 - 09/30/17 3:55 am 66’ Lightning drops out of gear  
Joined: Apr 2014
Posts: 40
usamike10 Offline
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usamike10  Offline
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Streetsboro, Ohio, USA
When accelerating in 2nd gear, especially when getting up to 4K rpm or higher the bike has the tendency to drop into neutral. The harder I accelerate the more likely this happens. This doesn’t happen in any other gear, any ideas what’s going on?

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#710041 - 09/30/17 6:48 am Re: 66’ Lightning drops out of gear [Re: usamike10]  
Joined: Dec 2004
Posts: 8,827
kommando Online content
kommando  Online Content


Joined: Dec 2004
Posts: 8,827
Scotland
Worn dogs on the sliding gear and worn holes on the gear it slides across into and engages with for second. Cute is to replace both gears.

#710044 - 09/30/17 10:24 am Re: 66’ Lightning drops out of gear [Re: usamike10]  
Joined: Aug 2001
Posts: 4,933
Rich B Online happy
Rich B  Online Happy



Joined: Aug 2001
Posts: 4,933
Stone Creek OH USA
2nd gear is on the lay shaft. The end play of the layshaft is shimmed against the DS of the case. Per BSA, the end play should be "just perceptible". Shims are available in 3 thicknesses to tighten end play.

Shift fork can be bent, make sure fork is perpendicular to shift rod

If you have standard ratios (most likely), then 2nd and 3rd sliding gears are interchangeable. Swap layshaft and maishaft sliding gears. Unless someone has already saved the gearbox in the past with this trick! Check the dogs first.

The mating gear may be worn. If so find one that isn't.


Life is too short to drink cheap, bad beer.
#710408 - 10/03/17 3:55 pm Re: 66’ Lightning drops out of gear [Re: usamike10]  
Joined: Aug 2001
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gavin eisler Online content
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gavin eisler  Online Content
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Posts: 3,291
argyll. scotland, uk
When my bike did this it turned out to be a badly worn cam plate and plunger.
The dogs are probably a bit worn on the sliding gear, I didnt replace it at the time, but did pay attention to the LS end float, it never jumped out after that.

Last edited by gavin eisler; 10/03/17 3:57 pm.

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#710495 - 10/04/17 12:44 pm Re: 66’ Lightning drops out of gear [Re: usamike10]  
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usamike10 Offline
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usamike10  Offline
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Streetsboro, Ohio, USA
Thanks for all the good advice, sounds like a project. I’ve never been into the gearbox, but I do have the manual.


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