TownsendsFJR1300, Thank you but that's just the flash making it look like that. I've double checked and no cracks or chips.
I'm having a mare of time getting the torx screws out holding the input shaft and bearings in.... They are punched to secure them but i can't lift the little flap so i tried drilling it off but again no luck. I'm starting to round them off if i try anymore and that will leave me 1 option... drill them out ! Anyone have suggestions ?
I know this sound kind of mean spirited but my buddy and I have been following this thread for 4 days now. We have a $10 bet on what it is. I said the noise has nothing to do with the transmission because the clutch would slip long before a tooth would shear off a gear. He said he wouldn't bet that it was a gear but definitely something in the transmission.
I kind of hope it is something in the transmission now because of all the work you have done. After looking at the pictures I can't help to think that the broken exhaust mount.
Good Luck
From Post #12:
Noise is only in 2nd gear.... Rest of the gears are normal. Its not a constant grinding noise, it comes and goes and gets faster as i go faster. It's like a couple of teeth have sheered off on 2nd.
I know as fact you can indeed, shear off teeth without the clutch as I did it on a YZ 125 two stroke years ago(coming off a jump). Second gear and second idler gear. One gear WAS a press on fit...
If I was in Adam's shoes, I'd gone the same route and done the same, tearing down vs leaving it and potentially/likely causing more damage..
In either case, he'll find the problem... No doubt in my mind...
If you can get it back to this stage and oil only the shafts and inner section of the gears bushings, any noise from friction of contact on the thrust surfaces will be 10X louder w/out the oil as a cushion.
Also - a quick flash card held up indicating the selected gear i.e. 1st gear, 2nd gear, 3rd gear would be great! I'm not the kind to talk either! lol
So recap - noise was only in 2nd gear under load or No load or both?
All gears are in contact all the time. If one was actually broke - bad stuff would have happened. Its why I think its about alignment more so than gear or shaft damage. Again, I suspect light contact from an adjacent gear. Because IT WAS NOT SUPPOSED TO HIT Neutral while in 3rd or 4th gear, it suggests the shift drum, shift rails, lockouts or lock-out detents allowed this to happen. So I vote one of the above is suspect for allowing partial gear engagement making the noise.
PS - this Trans has bigger gears and shafts than some CARS! Its the Tank of transmissions! it looks Bullet Proof!
Hi Adam, looks like you had a lot of difficulty getting those corroded bolts apart. That might be the hard part in all this adventure.
Do you know how the gears work? Just in case... 2nd gear is the pair on the right, furthest from the clutch. For the output shaft, it spins freely on the shaft and is only locked to the shaft when the right hand shift fork slides the dogs on 6th gear into the windows on second.
This is one area to look for wear. Are the dogs rounded on the ends or are the window edges rounded.
Another area to look is the bearings, which should turn freely and smoothly. They probably do. Usually, there is an anti-rotation pin in the bearing outer race. These are small and can be overlooked, make sure it hasn't sheared off or anything like that.
I think i remember seeing some rings in the outer bearings that controll the position of the entire gear shaft. These should not be worn and check the groove in the housing.
Have a look at the shift fork for signs of wear or cutting on the flanks. Sometimes these can flex enough to touch the gear, but flex back. If the right hand one looks bent instead of flat, that could be the issue
Assembling the gears and turning them you may be able to detect if one of the teeth got bent (unlikely) if it makes a one per rev droning noise while spinning. Perhaps you can put your hand on top of the right hand bearing while spinning the shaft to see if there are any vibrations. - WATCH YOUR FINGERS. If you are using a power drill to turn the shaft, keep your fingers clear. No rings or loose clothing near spinning stuff.
One more thing to check is the little shaft spacers between the gears. Make sure they are not unduly worn.
Good luck - check everything and if you can't get those star/torx screws out, leave them in.
I like the cardboard bolt finder - I used plastic zip lock bags and wrote down the bolt pattern on the bag
Oh nearly forgot - if you have time, you can have a look at this - not the same bike, but they are all the same
Slide1.jpg Photo by RichBinAZ | Photobucket
Hi Adam
In the 10th photo down... the shift fork with "5EB" and a 6 under it seems to have an odd mark just above the B - like the fork may have flexed and touched a gear. The forks apear straight to me and some marking at the chrome plated ends is to be expected.
The gear windows on that one gear appear a little rounded on one side and the polishing on the webs in between the windows is not severe, but some evidence of slip or a bit of difficulty getting it into whatever gear that is. If it was jumping out of gear you would know.
So what is making the noise when it is in gear?
Rich
Was that 2nd gear or have anything to do with second gear?
RichBinAZ said:In the 10th photo down... the shift fork with "5EB" and a 6 under it seems to have an odd mark just above the B - like the fork may have flexed and touched a gear