Aluminum particles all over the place 2018 300

5valve

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During slow ride gearbox locked in 1st, then freed and worked flawlessly again.
I do hear some noise now with clutch disengaged and occasional, could even be, extreme chain like rattle sound.

By hand, everything is rock solid, no play, rotates freely, no broken case parts, at least on the outside.

Since currently not really up to tearing engine again, I'd flush it and clean all rotating parts, clutch etc.. Whats would be better, diesel or gasoline?

3rd pic shows really amateurish oil cutout from rekluse.

Only alu, no steel, checked by magnet.

Any experience with that?
 

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I can't comment on the aluminium particles, but my gut feeling is they shouldn't be there

with flushing i have used parafin / Kerosene to flush the gearbox after a deep swim. If you cant get that, i would rather go with diesel over gas, just because it is closer to being an oil - and you are less likely to set yourself on fire
 
I'm with Swazi_Matt here, those particles should not be there ;)

Perhapse something is rubbing inside the gearbox? Did you split the engine at some point? Sounds like e.g. a shim may have been misplaced.

I think a flushing will do just that; flush particles out. And then I would assume more particles will be produced until you fix the root cause.

EDIT:
Could it be the water pump impeller that's rubbing?
 
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The gearbox locked and there's shrapnel everywhere and you want us to tell you it's ok to ignore it because it would be inconvenient?

Sure. Dave says; It's ok.

Start saving.

Wear armour for when it locks in 4th and the clutch doesn't save you.
 
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Time to find out for sure where those aluminum particles are coming from. Start disassembling until you find it.
 
I'm with Swazi_Matt here, those particles should not be there ;)

Perhapse something is rubbing inside the gearbox? Did you split the engine at some point? Sounds like e.g. a shim may have been misplaced.

I think a flushing will do just that; flush particles out. And then I would assume more particles will be produced until you fix the root cause.

EDIT:
Could it be the water pump impeller that's rubbing?
wouldn't the waterpump impellor rub on the water side, not engine side?
 
Engine was apart already 2 times, unrelated issue, main bearing failure.
Worked flawlessly for 30 hrs since.

Alu impeler is not damaged and cant enter gear/clutch.
Gearbox didnt get stuck, it seems like some foreign piece on the clutch side temporarily jammed under outer shift fork, freed instantly, and got ground all over the place.

No magnetic debris whatsovever.

I've inspected everything on the right side, and there is absolutely no damage or broken off parts from case, clutch basket etc. Checked clutch plate by plate..nothing unusual. @95 hrs like new.
Also, by my knowledge, the is no aluminum engine parts in the gearbox, except cases, so nothing should come loose, even alu washers are not present.

Flushed with gasoline today, will do some more, guessing 90% clean.

Might forgot sth in there that lasted 3 service intervals, time will tell.
 

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Sounds like it had a piece of Aluminum debris in the trans which is not impossible. I have previously posted on a half dozen shim washers I found in the crankcase of our 2003 DE300. I believe they were in there from the factory.
 
Interesting find, when removed pressure plate from clutch gear. Anodization still in place over cavitated/worn/ bad cast surface, so it was like that from factory. Therefore this is not the culprit.
Now cleaned soon test.
 

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Washed gearbox, poured 75W90 leftover gear oil to further flush, works great, silent, but maybe not clutch friendly if abused.
Its not thick oil, corresponds to 10w 40, good for final cleanup.
 
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Went for a ride, locked again. Freed afterwards. New particles, some bigger also.
Halved the engine...nothing special inside. Last pic..spring and ball were inside dropped oil. I do have wet mod starter mechanism, but never saw such spring in gg engine.
 

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If it was a roadbike I'd say neutral indication at end of shift drum.

Neither look gracked up enough to lock an engine.

Lay out gearbox and check against diagram for missing washers.

Check all clutch washers. Check everything close up for sign of mechanical violence.
 
That part in the red circle I don't remember. Is that from something grinding it? Also, you can tell the crankshaft side clearance is off by virtue of the shiny metal on the case where the red arrow is. Of course, it's been a long time since I've been in the bottom of a Gasser so maybe I'm just not remembering those two details.

I agree, check all washers and thrust bearings for proper thickness and placement. Something definitely isn't right.

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For me, spring and ball is some kind of check valve, but nothing like that on any 2t.

Encircled part will check the cutout, but it is most probably made for the gear.

You're right on the bottom end side play, but this is gearbox secondary shaft area. Will go through some old pics to check for polish being factory or "aftermarket"
 
I'd assumed the cleaned up are was std. Just looked at some pictures from my 07 in July but have gears in the way.

But SS109s 2nd circled picture is clearly where your swarf is coming from. That ain't right. That gear is walking where it shouldn't be able. Check the gear and meshing gear edge well. I think you may have got lucky that it just ground hard against the case rather than latching 2 gears at once where would have gone kaboom and put you on your side if at speed.
 
Damn if that was "the case".

I did find a pic from 1st dissassembly year ago...current one is 3rd.

Encircled cutout corresponds to cast roundness to fit the gear.
 

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Cool. So, what is grinding in there? I still would double check that location as best I can tell from the pics that cut out looked smoother in the before pic.
 
Damn. Completely unrelated I'm sure, but spring/ball bearing reminds me of kick starter rebuilds, way too many times, on my Maico's/XR/XL.

Also, the needle bearing where the red circle is reminds me of the ONLY bearing in bottom end of my 82 Maico 490 I couldn't replace. Worked great in Fort Hood TX for 20 min then nuked itself. Ouch!!!!
 
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