Had some time off over the holiday and decided to take on the transmission problems I was having.
It always sucks taking a bike apart you just put together. Oh well, at least I'm not fighting bolts that haven't moved on 40 years.
Got the engine out.
I'm just opening up the bottom end right now. First took all the bolts out from the top, then flipped it over and took all the bolts out from the bottom. I was careful to take the 10 big ones out in reverse torque order. All the nuts and bolts are in separate labeled baggies. Then the case split! No too bad, just working around it with a rubber mallet and occasionally a block of wood and a hammer.
At a first glance the gears and dogs looked fine. But when I get my reading glasses on and look at them from all the angles with a flash light, I can see where things are worn down. The shifter forks look fine, no bends and they are well within the factory manual wear limits.
So it looks like I'll be sending the gears off to
CycleX/. Might as well do it right and get their undercut gears on exchange.
I also took the time to clean up the mating surfaces. I have some TheeBond 1104 (equivalent to HondaBond/YamahaBond) for sealing up the case halves.
When that's all done, I'm going to flip it over and take the head off. I was getting some smoke at start up, so new valve seals for sure, probably lap the valves and put new rings in. If the pistons and/or the cylinders are in bad shape, then rebore and go up a size.