First Miles since purchase

[dgurovich]

I have a 57 Red Hunter that I just purchased. Got it running today and took it out for it's first 20 mile jaunt.

It pulls like a freight train!

I do have one issue -- 2nd gear engages well after shift and clutch release -- often 5 seconds or so. Once in gear, when I accelerate, it "chugs" and "bucks" until I shift to Third.

In all other gears no matter the speed, no bucking or chugging, so I figure that there's something in the Burman Gearbox that is causing this issue in Second gear only.

it shifts fine from 3rd to second on decel, but as soon as you start accelerating, it just starts bucking and making slipping/mechanically nasty noises. All other gears are perfectly fine.

Thoughts?

[Mick D]

Hi

My advice would be to stop riding before you do more damage! It sounds like the second gear dogs are not fully engaging or you have missing gear teeth in the second gear train. If it's an issue with the dog engagement you may be able to sort it by shimming. In either case the gearbox needs to be stripped for investigation, (take lot's of dis-assembly photos )

Regards Mick

[dgurovich]

I assume it's like my matchless -- Remove engine first?

[dgurovich]

If this doesn't involve the final drive, can I just access this from the case cover without a complete engine out? I think the difference is an afternoon's work vs a week's work (You get bit by the "while you're in there" bug and start fixing all kinds of things).

[Simon.Gardiner]

You can strip the gearbox without taking the casing out of the frame, but if you want to take the gearbox out I think you'll have to take the engine out. (Edit - on mine anyway!)
With a bit of inventiveness (and maybe luck ) I think you can even replace all the final drive bits with the casing in the frame - but hopefully you won't have to go that far.

Not sure how far you've got to go with the primary side, now I've started thinking about it I'm wondering if you can actually pull the gears out without disturbing the mainshaft and clutch at all! However, worst case you'll need to get the clutch, primary outer case and primary chain off so you can get the clutch chainwheel away from the mainshaft (and back on again) without losing some needle rollers and spacer/shim washers.

The symptoms do sound a bit similar to when a friend lost a tooth from 2nd gear on his 3-speed Albion box - lots of surging.

Good luck!

SG

[dgurovich]

Bingo. Tooth decay!

I expect DraganFly is my go-to for the gear and possibly bushings, etc? Would they have a "rebuild kit" with the normally replaced goodies?

[Mick D]

Hi

Overhaul kit is here:

https://draganfly.co.uk/shop/100216/gb- ... CK-ADV-005

Good VFM in my opinion, I used one on my re-build.

Glad for you it's an easy fix

Regards Mick

[JohnnyBeckett]

hi it can be the bush in the second gear they tend to move and stop it going into gear, i had it last year on my NH and you can the box out without removing the engine remove the clutch side gearbox / engine plat and remove the outer and inner gearbox case and and you can get the main gearbox case out and change the bearing and bushes

[will_curry]

I'd be interested in seeing some pictures of the broken gear. In my experience
GB boxes are pretty robust. What shape is the meshing gear in and are there
any signs that the mainshaft has bent?

You have a really nice bike there that someone has put a lot of effort into.
It'll be interesting too to hear how it compares to your G80.

[dgurovich]

Got into it -- Gearbox is fine. Clutch hub had a snapped stud. I'm going to go ahead and replace as much as I can of the parts. Hub is quite chewy. I noticed Draganfly didn't have the hubs (I got everything else from them) -- I have a source in the U.S. -- but for future reference, is the hub proprietary or is there a cross-reference? (57 Red Hunter)