Bandit 1200 5th Gear Problem

[Ted M]

Hello

My Bandit 1200 has started jumping out of 5th gear at 3 - 4000 rpm. I stripped the engine and 5th and 3rd gear are quite badly worn on the input side. On the output side they are worn but not as bad, but I have noticed slight burring on the 2nd gear  dog holes. I intend to renew the gears on the input side, does anyone know of anywhere cheaper than Robinsons Foundry? Is there anything that I can do about the burring on the 2nd gear dog holes output side? Any help or advice would be appreciated.

[clivegto]

I replaced my b12 2nd gear a few years ago now, it was the rounded dogs that cause it to jump out of gear. They apparently can be recut but I got new ones from Robinsons foundry with the OSS 10% discount. You could put second hand ones in but they do tend to be worn somewhat already. 2nd and 5th dogs mesh together if I remember correctly, also look at the fork selectors for wear.

[Ted M]

Thanks clivegto did you do both in put and out put or just the worn gear. It looks like its going to get expensive if I go new, but its starting to look like the only way.

 

[Fula28]

Get them undercut by Rodger upperton proper preventative maintainance! 

 

[clivegto]

I only did 2nd but should have done both really. B12 dogs are undercut as standard.

Herd Rodger had hurt his arm really badly, might not be able to help, you could always ring him though.

[Ted M]

Thanks for the advice guys I'll replace both input and output.