after a rather emotional motivational speach from Mark at mac1 i decided on starting the gear box replacement. So all was well till i started reading the haynes manual. Im pretty sure the Rating of difficultly is based on 1 spanner is easy 2 spanners is hard and 5 spanners means that even kawasaki would write it off at that point.

So to remove the gearbox you need to drain oil and water (normally on the desk your working on and the floor. not to mention the rest on your hands and jumper :O)

well after i removed everything off the engine i followed the 1000000 page guide to taking the gearbox out. so haynes manual says i need to remove the clutch which im sure i dont need to but i did anyway.

then it tells you to remove the gear selector arm thing and the springs.... sorted THEN it tells you not to mix them up. GREATTTTT maybe warm me before i put them in the I DROPPED A BOLLOK BOX.....

anyway the old engine is stripped and its was done in a few hours which is ok i guess but a rebuild will not be fun.

ANYWHOOO. its not easy so if you need to replace it due to the 2nd gear issues then bin it and buy a new one lol


DAVE J

Gearboxes all tend to come out/apart/etc. in the same way on split crankcases. All very similar setups, gear selector drum, forks, etc. Yep, it's a pain, now try and do it in the back of a Transit, poorly lit at night... just to get at a burnt to death central fork.

More recent engines, particularly in the smaller (racing) one litre bikes, now have cassette gearboxes. I don't have one (I have the split-the-crankcases GSXR/R1 variety), but it you go that way it all looks very much easier on paper.

I've just replaced the R1 clusters and drum on a 5VY that exploded without warning up Avon Rise a couple of weeks ago.

Fowlers are your new friends!

I had to do the same job on my Thundercat engine (Yamaha 600). The gearbox case does actually split into two halves, and anyone with a bit of sense would make sure the two halves are bolted together from the outside. But no, to get to the gears you have to start at the camshaft cover!

It took me two days in total to replace the relevant parts to fix the second gear issue. Roughly one day down and one day back. And then a quick trip to the local engineers to remove and helicoil a couple of broken exhaust studs!

rule 1 of the instructions, always read BEFORE starting any work
hope it all works out!

They are a pain :-)

Rule 1 noted down :-)

indeed

spare a thought, in my haste I stripped the box, following the said manual, and managed to put it all back together at great expense, only to find it was the starter motor which outwardly looked fine but upon inspection was totalled internally. Bugger...I believe this is what is referred to as cheque book education.

Ok you win lol....,