88 Evo 4 Speed Rebuild
 

Well, after shredding 3rd gear, the gearbox was torn down and found 3rd main broken in half, a tooth broken on main 2nd and misc. damage to surrounding gears and forks.

I would attach a photo, but I guess I need a few more posts. After reassembly using new Andrews gears and replacing brass forks with steel, polishing the shift cam and new most everything else including a Zippers trap door, bench tested fine with smooth gear changes. Shimmed for endplay at approx. .012 for the main shaft and .010 for the counter. Gear spacing well within the .040 to .080 min.max.

After installation, the test drive was not very positive! Could engage only neutral, 3rd and 4th gears. Clutch adjustment and free play is good, and no nasty sounds. All I can think of is that the counter shaft 3rd gear is not sliding properly to engage 1st and 2nd. Anybody got any been there done that advice? I'm getting ready to pull the gearbox and hopefully will find something simple. Any thoughts on what would prevent CS 3rd from sliding properly? The shaft looks fine and all worked well on the bench.

Thanks for any input or insight.