pgtips
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 posted on 27/6/09 at 03:14 PM |
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Arrhhh my gearbox
Coming home from a nice blast earlier, all ok till I pulled out from a juction 1st, 2nd 3rd missed gear revs to the rev limiter then gear got engaged
on it's on and then a hell of a rattle coming from under the bonnet. Good thing was that I was like 200 yards from home.
Now what it does. The noise will not alter pressing the clutch or not. Clutch down, sellect 1st gear and the rattling will go.As long as I keep my
foot on the clutch and is in first gear then I can rev the engine and no rattle. Then I select neutural and the rattle will come back. Driving the
vehicle will rattle on all gears and it seems to be speed related too ie the faster il go the more rattle will be. Any ideas that what it may be?
Now I am sure I l have to strip the gearbox but will I be able to do it with the engine still in the car?
The engine is a 2003 954 cc fireblade.
Thanks everyone.
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Steve G
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| posted on 27/6/09 at 03:37 PM |
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I'd be tempted to pop the clutch plates out first and check the clutch basket to see if thats in one piece.
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gingerprince
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| posted on 27/6/09 at 05:43 PM |
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quote:
Originally posted by pgtips
Now I am sure I l have to strip the gearbox but will I be able to do it with the engine still in the car?
If it does turn out you need to strip the gearbox, then it's a crankcase split job, so you'll need to remove the engine.
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pgtips
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| posted on 27/6/09 at 08:07 PM |
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Thanks fellas.
Update***
I have removed the clutch and basket but have found nothing wrong with them.
Turning the Input shaft by hand is free for two turns and then it hits a tight spot so I think one of the gears (probably 3rd gear) lost a
teeth?
So tomorrow is engine out and separate the crankcase.
Happy days.
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dean100yz
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| posted on 28/6/09 at 09:12 PM |
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Ha just come back from a drive today myself. Ive had mine back 1 day and its started jumping out of 2nd and 3rd when under load at high revs!
Think Ive got the same problem
Man Ive had no luck with mine!
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pgtips
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| posted on 29/6/09 at 07:47 PM |
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An update for those are interested 
I have split the two half's expecting to find a broken teeth on one of the pinions. To my suprise I din't find nothing  . had a good look
and that's what I have found.
^^^^ Crack on the 2nd gear pinion of the Input shaft.
^^^^ Mark on the 2nd gear pinion of the Input shaft.
^^^^ Fork badly marked on the 6th pinion of the output shaft
^^^^ Wear of the 3rd gear pinion of the output shaft. (Is this bad enough to worry about?
Any of the above pictures will anyone say that will give the rattling noise I had experience from the gearbox?
What you guys think?
If I die, my biggest fear is that my wife sells all my toys for the price I told her I bought them for...
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pgtips
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| posted on 29/6/09 at 10:06 PM |
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Hi again. Can anyone tell me if the gearbox on the link bellow will fit mine ( 2003 954cc )
Link
If I die, my biggest fear is that my wife sells all my toys for the price I told her I bought them for...
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pgtips
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| posted on 30/6/09 at 08:50 AM |
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Anyone??
If I die, my biggest fear is that my wife sells all my toys for the price I told her I bought them for...
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eccsmk
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| posted on 30/6/09 at 08:57 AM |
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here worth a read mate
HTH
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pgtips
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| posted on 2/7/09 at 07:02 AM |
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quote:
Originally posted by eccsmk
here worth a read mate
HTH
Thanks fella, I had a good read.
I managed to find a complete input and output shaft complete with gears, drum, and forks in very good condition (the sellers words that is) on fleebay
for £150.00,....bargain me thinks.
Should be with me today some time.
Thanks for your replys, and a special thanks to Andy @ AB Performance. That guy loves his fireblades, and he gave me bags of advise about the gearbox
problems.
Thanks again.
If I die, my biggest fear is that my wife sells all my toys for the price I told her I bought them for...
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