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860 drops out of 2nd gear

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Betsy

07-19-2002 07:21:12




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When going down a hill, and especially when hitting any kind of bump, my 860 drops out of 2nd gear and into neutral. If I anticipate this and hold the gear shift it won't drop out. My friend has an 850 and says his does the same thing, also in 2nd gear only. I am planning to have my 860 apart this winter to rebuild it. Is there anything I can do to correct this 2nd gear drop out problem while I am in there? Larry

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Phil (VA)

07-19-2002 07:37:26




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 Re: 860 drops out of 2nd gear in reply to Betsy, 07-19-2002 07:21:12  
Probably not a gear problem. More likely the shift lever ball is worn, or rails worn or bent. Could be as simple as replacing shift lever.



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DC

07-19-2002 08:44:18




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 Re: Re: 860 drops out of 2nd gear in reply to Phil (VA), 07-19-2002 07:37:26  
First thing to try is take out the middle of the three plugs on the left side of the transmission. There is a spring in there that you can tighten up with a small washer inside the plug. This may fix it. It did not on mine. The next step if this did not work is to take the transmission out. Once it is out check for end play on the lower shaft. If there is any you may want to remove the shims on the back lower bearing. If there are no shims you'll need to put new bearings in it. Once you have it this far apart check the shift couplers inside for wear. This requires a major dissection. The couplers are all the same and run about 70 bucks.

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