Tranny Failure

[Jacob 'Berg]

Riding back to staging area today after trail ride. Shifting from 5th to 4th gear and the bike suddenly goes into neutral. I proceed to shift down and I hear a clunk and the rear wheel locks up. Counter shaft will not move even while pulling in on clutch. Shifter shaft locked up. The kicker will not move either. Any ideas? I am going to pull the side cover when I can and take a look.

 

[Zman]

You will likely need to spit the cases but start by pulling off the clutch inner cover an see if anything looks odd there first.

 

[Jakobi]

RHS engine cover. Check the selector shaft assembly as first point of contact. Some have been known to break away from their weld and cause issues.

 

[Jacob 'Berg]

Thanks, just guessing at this point, but selector shaft, clutch, and idler gear seem likely possibilities...If idler gear is the culprit, will there be any way to verify with RHS cover off?

 

[gg3]

oh........thought the thread was about something else

 

[paulos]

oh........thought the thread was about something else

Some of them are hard to pick

 

[Zman]

Agreed it seems that this forums search function is somewhat limited. Unless I am not seeing an advanced option, it appears that the search function only looks for "any" of the searched words and not "all" of the searched words.

 

[Moto7man]

RHS engine cover. Check the selector shaft assembly as first point of contact. Some have been known to break away from their weld and cause issues.

Yep, check this first.

 

[gasmonkey]

Sounds like the selector/selector drum has selected another gear without deselecting the original gear,ie is in two gears now hence lockup.
If it's done under full power the tranny implodes.I know I've seen it done.
Very expensive.

 

[Jacob 'Berg]

Drained the oil last night and there was a small piece of sheered steel stuck to the magnet. About .25" long and maybe .125" wide and deep. Not encouraging, but did not see any other material in the tranny oil or on the magnet of the drain plug. Going to pull the side cover tomorrow morning, but it seems that the cases will need to be split regardless if there is debris in the transmission.

 

[gasgasman]

Can you post a pic?
Sounds like a chipped gear tooth.

 

[twowheels]

Drained the oil last night and there was a small piece of sheered steel stuck to the magnet. About .25" long and maybe .125" wide and deep. Not encouraging, but did not see any other material in the tranny oil or on the magnet of the drain plug. Going to pull the side cover tomorrow morning, but it seems that the cases will need to be split regardless if there is debris in the transmission.

You'll want to pull the motor if you haven't already, because you're likely in for a case-split.

There's nothing particularly tricky about the job, you just need to be thorough about cleaning every nook and cranny and making sure all of your bearings are still good.

 

[Jacob 'Berg]

Can you post a pic?
Sounds like a chipped gear tooth.

I will try and post up a pic of the fragment when I get home tonight.

 

[Jacob 'Berg]

Pic numero uno.

 

[Jacob 'Berg]

Pic numero dos.

 

[Jacob 'Berg]

Looks like a spring?

 

[twowheels]

I wouldn't think that was a spring, but rather just the form it took when it peeled off.

Pull the motor, get the right side cover off, pull the clutch, and see what you see. If there are no obvious signs there the issue lies deeper inside.

 

[Jakobi]

I wouldn't think that was a spring, but rather just the form it took when it peeled off.

Pull the motor, get the right side cover off, pull the clutch, and see what you see. If there are no obvious signs there the issue lies deeper inside.

What Steve said.

I'm assuming it's still locked up in gear, so as per original, get the rhs engine cover off and have a gander. Post up some pics if you're after further opinions or not sure how it should look and then take it from there.

 

[Jacob 'Berg]

Got the side cover off. Here are some photos. I see nothing wrong from this side. I can get the motor to turn over by turning the clutch basket. So, I guess I will be splitting the cases after I give the bike a bath.

 

[Jacob 'Berg]

Another photo.