Gear box issue

[mikesaa309]

Hi,

Recently when riding home from a ride out, something in my 1997 bandit 600's gear box decided to break. After having the gear box out I found out that a gear dog had snapped off and can only assume this then broke two teeth of one of the gears. Luckily gear box on bandits can be lifted out from the bottom so no need to take top end apart and brought a gear box on ebay for 35 quid as a complete assembly.

I just want to figure out why the dog broke is it down to the fact sometimes I haven't shifted gears properly so it gets stuck inbetween gears which I'm not sure if it's just me being retarded or if something is slightly wrong with the gear box somewhere? Or is the dog breaking to do with something else I just don't get why it is just that one out of a possible 3 on the gear it broke off when if It is due to miss shifting then surely all 3 dogs are prone to the same amount of wear and so all of them should have broken?

Also can anyone tell me why this made the clutch go soft and the clutch lever wouldn't return all the way?

[331X2]

Is that why you're called sprocket?

[Robby]

If the gearbox is stuck between gears (false neutral) then no gear is engaged. It is meant to be impossible to select two gears at once, if this is able to happen then you have a shifter drum/selector fork problem.

The usual way to strip teeth off gears is by treating the box very badly - rough shifting with no clutch whilst you're on the power. Bonus points for very old or very little oil, but I would expect that to kill the engine before the gearbox.

Usually if the clutch goes soft it's because of lack of fluid/leak in a hydraulic system, or the clutch bolts unscrewing themselves if someone has changed the plates and not tightened up the bolts. I hate doing that job, because it's a fine line between too loose so the bolts unwind, or too tight and snap a tower off the aluminium basket.

So both of your problems are likely down to cack-handed maintenance in the past.