Another 'spare' bike

[Drunkn Munky]

Loving the obligatory brands shot

[Tim400GB]

Tis my destination of choice

Some not so great news.
After riding the bike it seems to be slipping in and out if gear in top. Fine in the rest
Awesome ..... not

So when I get some spare time the next steps are
1. Check the rear set lever and linkages are operating correctly.
2. Get the drum and selector forks out and inspect.
3. With the sump pan off hopefully be able to inspect the gear dogs through the bottom
4. If the dogs are worn start getting the engine back out for splitting.

[Tim400GB]

So this has happened


Then this happened


This turned up from Graeme France (very helpful although its actually missing a gear and thrust washer)


This turned up from Rick O (thank you again Rick)


And this turned up from Rick O (a birthday present from the parents)


Just need to get some time to put it all back together again

[Tim400GB]

So while waiting for the missing gear and thrust washer to turn up I thought I'd look at the busted gearbox to see what gave in.

Here it is all together.


And all apart for inspection.


And what I found was this.
Working my way from the input shaft clutch end.

5th gear had rounded dogs.


As did 3rd. You can also see excessive side wear (& heat) in the middle of the gear where the selector sits.


6th to 3rd dogs are also well rounded. On 6th you can see the face of the dogs are scored where its been slipping out of gear.


And with 6th slipping out of gear this has put a side load onto 2nd causing scoring to the gear and squashing the thrust washer well out of shape.


And with the gear wanting to slip out it has also taken out the selector trying to keep it in place.


6th on the output shaft also had slightly worn dogs but not really that bad to picture.

All the worn parts removed (hopefully be able to find a few spares and rebuild it at my leisure)

[Tim400GB]

After the disaster of the zinc coating burning off the manifold.
(Was told not to do it but tried it anyway)

Decided to blast it again and paint it black.

Mums and girlfriends look away

[Drunkn Munky]

thats gunna stink, best make yourself scarce when she gets home

[Tim400GB]

Yeah man made a quick exit lol.

Been a busy bee today, sorry not that many pictures but I was on a mission to get the motor sealed up.

All done


The aftermath

[Tim400GB]

Well after this weekend she's near enough back in one piece, just the fairing to go back on.
Has been filled with fluid again and she's a runner once more.

Just need a bit more garage time then it's the shake down run "take 2"

Oh yeah and now the Rick O ecu with the HRC map has been fitted.
Has got the wires for a shift light too so prob fit one at some point soon

[Tim400GB]

Found my fuel tap was leaking quite badly, Rick Oliver to the rescue again (many thanks Rick).
So I got it rebuilt today.




Went for a shake down run this morning. All gears working now, just need to double check for any leaks.

[Tim400GB]

Santa came bearing gifts from Rick Oliver



Got the old nc30 linkages and bmw shock out.
Need to get the original red spring back on it now but all the shops are closed.

Edit:
Woohoo DrunknMunky to the rescue.
Thanks to him we were able to get the spring changed and I could get the bike back in one piece.