Tranny Rebuild
- Thread starter mr hunt
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Mittzy
The Hooligan - Just Doing Stuff
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Get em back cut while they are out
Ok brains trust...no bent selectors either. Everything operates as is should on both i/o shafts.
To recap the symptoms - morning ride to work and 1 thru 4 are fine and selected as normal at various loads. Went for 5th and she sounded like I'd emptied a bag of marbles into a washing machine. Nursed to work with no other issues.
9hrs later and decided to ride home the slow way in 1 2 and 3rd. No issues other than LOTS of mechanical noise at start up but that disappeared after a few minutes of idle and slow 1st gear.
Got brave/stupid and tried 5th @ 60kph. Shifted fine ... played a game of row8ng up and down the gears and eventually she ground in 5th again and wouldn't engage.
I have had issues with a slipping clutch at higher loads but i think if it was a clutch problem it would be evident in all gears?
I also wonder if there is an oiling issue on the selector drum. Even when split open it can be difficult to select 5th by hand and the output 5th selector stick in the drum. This one is probably clutching at straws though...i imagine under normal load /rpm it will move just fine...
Any theories? Hunty is perplexed
cootertwo
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That is a bummer, not finding something obvious. I would be quite peed off for sure!
Claviger
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Claviger
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The extra mechanical noise at start up, to me suggests input section issue.
Only having issues going into one gear suggests drum, fork, or dogs.
The intermittent nature suggests it’s not too far from “in spec”.
I’d be looking for a slightly not true fork, a worn, damaged or out of spec shift drum, and checking dog corners on 4th/5th.
Kind of sounds like it failed to go into 5th and bounced between 4-5, it’ll leave evidence on the fork and dogs by wearing the dog corner and the load bearing portion of the fork will show some galling.
Check all bearings for runout, if ones got extra play it could certainly cause an intermittent engagement issue. It could also be the cause of cold start noise until oil takes up the slack in the bearing.
Beyond that I am at a loss remote diagnosing lol.
Good luck man, please let us know when you know!!
Only having issues going into one gear suggests drum, fork, or dogs.
The intermittent nature suggests it’s not too far from “in spec”.
I’d be looking for a slightly not true fork, a worn, damaged or out of spec shift drum, and checking dog corners on 4th/5th.
Kind of sounds like it failed to go into 5th and bounced between 4-5, it’ll leave evidence on the fork and dogs by wearing the dog corner and the load bearing portion of the fork will show some galling.
Check all bearings for runout, if ones got extra play it could certainly cause an intermittent engagement issue. It could also be the cause of cold start noise until oil takes up the slack in the bearing.
Beyond that I am at a loss remote diagnosing lol.
Good luck man, please let us know when you know!!
Tested for runout and all is good...unless my little bro gave me a dodgy dial gauge ..
Forks are only 13k old (replaced new this time last year) and don't show any signs of wear.
How would one know if one's selector drum was worn? It "looks" ok.
At this stage I'm leaning towards dogs just not engaging properly so will go undercut route and whack it all back together
Forks are only 13k old (replaced new this time last year) and don't show any signs of wear.
How would one know if one's selector drum was worn? It "looks" ok.
At this stage I'm leaning towards dogs just not engaging properly so will go undercut route and whack it all back together
Claviger
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No idea on the drum tbh, it’s a complex shape to try and check.
If everything measured out right, forks are straight, bearings good, it leaves... drum, gears, and the little spacers between things.
Assuming everything checks out, your plan doesn’t sound unreasonable, I know my second gear functioned a bit wonky and then all the sudden it didn’t work at all and it was rounded dogs. Sounds like maybe the same thing, your 5th worked fine up until a certain wear point and then it stopped working right.
If everything measured out right, forks are straight, bearings good, it leaves... drum, gears, and the little spacers between things.
Assuming everything checks out, your plan doesn’t sound unreasonable, I know my second gear functioned a bit wonky and then all the sudden it didn’t work at all and it was rounded dogs. Sounds like maybe the same thing, your 5th worked fine up until a certain wear point and then it stopped working right.
albertaduke
former airline pilot without the big bucks
here I am a neophyte when it comes to inner parts of the transmission but I had a problem with my transmission 2013 roadster when in 4th or 5th at about2300rpm and up a "slapping" noise for lack of better word was felt through pegs and frame really strong . when the transmission was removed the mechanic found the circlips between 4th and 5th ( do not ask me ) was scarred badly after the rebuilt with new circlips and 4th gear everything was just fine no more slapping maybe just take a look at that circlip
That was my problem last time...all the clips are fine this time round. I kinda hoped it would be a clip or spacer because it's a quick fix...I'm also kinda relieved thats it not any of those parts because I'm the one who put it all back together
