thirdgenlxi Posted April 20, 2013 Report Share Posted April 20, 2013 Well for the past couple months now my bike has been getting rather picky about staying in 3rd gear. It wasn't 'that' bad, but it has been getting progressively worse, so finally had to tear into it and get it all fixed up. Got all the parts I needed to fix it, and had a little time since we're not riding this weekend (going to the GNCC races again this weekend!), so decided it would be a good time to tear it apartWent pretty quick.... I rode it to work yesterday, rode home (carried all the tools I'd need in a backpack and tankbag), got home a little after 6pm, got started on it about 6:30 or so, and it was out and ready to go by 8:30. Not too bad.... coolant was still steaming when I drained it and motor was still warm when I loaded it into the back of my car, LOL. The little A-frame idea worked like a champ! Hard to see in the pic but the whole bike is actually hanging in the air. I'm not gonna lie though, I really do wish I had a cassette style transmission that didn't require pulling the motor out to do this, lolTook it into work with me this morning to tear it down. Boy was she dirty outside... the rural roads I ride on around here are so much dirtier than other places I used to live. Had to do some scrubbing on the outside for sure. The valve cover gasket was also leaking a little bit too so that didn't help any (it's original.... got a new one)Inside though... nice and clean. Oil still nice and clean too for having almost 6k miles on itOriginal clutch still hanging in there and looking good (256,138 miles)Once again..... squeeaaaakkky clean inside, always makes me happy to see. Regular oil changes FTW!Bottom end looks brand newAnd here would be my problem..... gear dogs on 3rd rounded off, and of course 6th too since it meshes with 3rdAnd got the shift fork a lil bit tooGot the new gears put in and trans back together.... guess I have my work cut out for me monday when I go back, haha. Then I've gotta do a valve adjustment as well.... fun fun. Should have her back together and running again this next week sometime and back to our usual weekend rides next weekend 1 Quote Link to comment Share on other sites More sharing options...
GuardRail-Mike Posted April 20, 2013 Report Share Posted April 20, 2013 I wish i had this kind of knowledge Quote Link to comment Share on other sites More sharing options...
thirdgenlxi Posted April 20, 2013 Author Report Share Posted April 20, 2013 I wish i had this kind of knowledge It's really not all that hard, especially with a good factory service manual.... pretty much walks you right through it. It's just nuts & bolts.... and maybe a few other oddly shaped pieces as well, lol Quote Link to comment Share on other sites More sharing options...
ReconRat Posted April 20, 2013 Report Share Posted April 20, 2013 That's pretty darn worn. Seen troubles from much less. Dang soft metal, or mismatched hardness of mating parts. Quote Link to comment Share on other sites More sharing options...
thirdgenlxi Posted April 20, 2013 Author Report Share Posted April 20, 2013 That's pretty darn worn. Seen troubles from much less. Dang soft metal, or mismatched hardness of mating parts.Yea this is the second time now having to fix 3rd gear.... originally started popping out (and shifting itself down to 2nd) back in 2008 at 114k. Fixed it and it's been good as gold up until a few months ago.... wasn't nearly as bad this time and wasn't going back to 2nd, just kinda jumping out for a quick second then re-engaging (which made for a good jolt if you were on the gas). So the first replacement made it 142k.... we'll see how long this one lasts Quote Link to comment Share on other sites More sharing options...
ReconRat Posted April 20, 2013 Report Share Posted April 20, 2013 I'll bet that the parts were only surface hardened, and that won't last forever. Quote Link to comment Share on other sites More sharing options...
Mr Anderson Posted April 20, 2013 Report Share Posted April 20, 2013 I wish i had this kind of knowledge I agree with you there. This is a great thread. I like the work and the pics. Thanks for sharing. Now I just need to go get my manual lol.246,300 miles that's amazing. I have 271 miles and not even close Quote Link to comment Share on other sites More sharing options...
12oclocker Posted April 20, 2013 Report Share Posted April 20, 2013 cool thread ;-) Quote Link to comment Share on other sites More sharing options...
thirdgenlxi Posted April 20, 2013 Author Report Share Posted April 20, 2013 I agree with you there. This is a great thread. I like the work and the pics. Thanks for sharing. Now I just need to go get my manual lol.246,300 miles that's amazing. I have 271 miles and not even closeHaha you'll get there! Just takes some time and lots of consistent riding Taken me 8.5 years to get this much on mine.... it started life with me at 3 miles. Actually haven't updated my siggy in awhile.... right now she's at 256,138 as of last night when I dropped it out Quote Link to comment Share on other sites More sharing options...
NinjaNick Posted April 20, 2013 Report Share Posted April 20, 2013 cool thread ;-)Oh, he has more threads. I always read his threads. His bike has came a long way. Makes me want to see how long my 14 can last...even with a turbo in time. Quote Link to comment Share on other sites More sharing options...
thirdgenlxi Posted April 28, 2013 Author Report Share Posted April 28, 2013 Thanks guys . Still don't have it back together just yet, but just cuz I'm waiting on a few gaskets and o-rings that I had forgot to order beforehand (or didn't know I'd need). Had to get a valve cover gasket (was still original.... found leaking just a little bit), o-rings for the oil pick-up and pressure relief valve, and the o-rings that go around the spark plug holes on the bottom side of the camshaft hold down plate. Hopefully they'll be in early this week and I can get it all back together. Other than that everything else is done... trans is fixed and cases back together, valve adjustment done, just waiting on the gaskets and I'll be setAnyways, a few more pics....Original clutch still measures well in spec (2.4mm)Top end like brand new.... literally looks like zero wear on the cam lobes, journals, thrust bearing, etcCertainly can't complain.... Rotella T6 has done me well! Quote Link to comment Share on other sites More sharing options...
thirdgenlxi Posted May 14, 2013 Author Report Share Posted May 14, 2013 Just a little update..... all finished! I didn't want it to take as long as it did, but just as luck would have it, soon as I get it apart it gets crazy busy at work and I have no time to work on it, and then on top of that I had to do a side job on my buddies R6 (valves all out of whack), and then some work on his trailer too. So mine had to kinda take a back burner for a bit as he was kind of in a pickle with a trackday scheduled soon and needed his bike. But was finally able to get her all finished up and back home.... ready to go inStarted saturday and got the engine hung back in the frameHad to start her up and make sure all was well..... sounded good, so filled up the cooling system and bleeding the air out herehttp://www.youtube.com/watch?v=6dnwUUfCKHYFinished putting plastics back on and gave her a good wipe down to get all my nasty greasy fingerprints offAaaaand.... ride time!! Just a quick jaunt down my road and back. The audio is messed up on my GoPro right now (trying to figure out if/how to fix that), so that's why all the wind noise (that's in the solid waterproof case). But you can kinda hear it.... running and shifting beautifully! Sooooo nice not jumping out of 3rd anymore, god that was freakin' annoying, hahahttp://www.youtube.com/watch?v=1gmIi4k8YZcNow back to our regular weekend shenanigans Quote Link to comment Share on other sites More sharing options...
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