83 XJ900RK Falling out of Third Gear

So third gear decided to give up the ghost today (83 900RK, 29K miles) :evil: ...
All other gears grab and pull :? .

When downshifting from 4th to 3rd, I get engine breaking.
From 2nd to 3rd, the shift lever is easy, no clunking, no grinding.

However, any attempt to accelerate whilst in 3rd gear ends up with the bike popping back into 2nd or flying around in between 2nd and 3rd. Scared the p!55 out of me on a deep turn today.

It feels like the shift drum isn't locking into place in 3rd gear. Don't know if it's the drum or if the shift fork might be a little out line?? Just got her back up and going and I'm not really interested in splitting the case right now, but so be it. Good excuse to redo all the seals I guess :roll: .

Suggestions or diagnostic tips please and Thank You.

 

Went through the clutch cable and return assembly last night. The cable was really sticky before a good oiling, but to no avail. Still dropping out of third.

I'm wondering if this is strictly transmission based or if a new set of clutch plates and springs will do the trick? Might redo the clutch before I get into splitting the case.

Still looking for suggestions from anyone who's had these engines apart. Maybe some nice pics of the guts from previous tear downs. Maybe i'll start one here in a week or so after I've given up hope...

 

http://www.xjbikes.com/Forums/viewtopic ... +gear.html

 

Thanks for the pointer to reading materials. Not particularly looking forward to the work involved or the loss of time on the bike, but I am looking forward to having the excuse to go through the mill bit by bit.

Looks like clutch plates and springs first followed by a full tear down.

 

New clutch bolts too.

 

Got a chance between paying job projects to do some real work. Mill is split, problem found.

The #3 shift fork is all sorts of burnt up and worn out in strange places. The gear dogs look a little worn as well. I'll always take hints, especially with sourcing parts at this point in time. Leave comments in gallery or discussion on this thread if you would.

Didn't feel like re sizing all the pics (can someone teach me to post so that I don't have crush the pics down to 500X500) so I started a gallery, "The 900 Crank Case Split" under my name.

Making the parts list tomorrow afternoon. Seals, Seals, Seals. Sounds like I'm going to the d@#m three ring on this one.

So, needless to say. If anyone is looking to remove and split and 900RK case, I have done it and will pass on any knowledge I have acquired in the doing.

 

I have a 900 Engine to sell if you need one.