Well, this isn't good

SS109

Well-known member
At 418 hours I changed my gear box oil and found metal. Pulled the side cover and can find nothing wrong so I guess it's in the transmission. Guess I'm splitting the cases. On a side note, found my primary nut hand loose. Thank god for the left hand threads or it would have completely come off.

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I'm in a total state of confusion. I have completely disassembled my engine yet I can find no failed bearing anywhere. I even went so far as disassembling the transmission shafts and everything looks good. I only have one bearing, the inner water pump, that feels a little rough but that's it.

I think I'm going to take a break and come back to it with fresh eyes later.
 
Odd but surely the gears have just failed. When GG went under 1st time I bought a clutch and gearbox from a member on this site just in case, despite no talk of any failure.

I read this and immediately thought to offer you mines except I no longer own it. A mate does. He has bought a new bike since then. But freight from New Zealand will likely be prohibitive as after covid it went silly.
If you can't find a box and an early one, probably 2008 will fit let me know and I'll see if he'll part with if for the same as I sold it to him (free).
 
I can't tell how big those parts are - could they be power valve parts which dropped into the clutch cavity through the hole in the clutch cover?

It's been 4 years since i owned my GG300, so i am going from memory here.
 
I'll take a wild guess: Those fragments look like pieces of JB Weld that were formed for a purpose. I would check you fill/drain areas and the cases in general to see if there was a repair inside that maybe failed.
 
Debris is magnetic. Pieces are roughly 4 to 5mm long and 2 to 4mm across.

I haven't looked at it again yet but I found no evidence of anything other than the primary nut being loose and one water pump bearing feeling a little rough. Everything else appears perfect.
 
Ok, I have checked, literally, everything in the bottom end that is there. I still can find no evidence of any bearing coming apart. Also no signs of damage other than where the loose primary nut was rubbing the outer case cover and the Rekluse clutch cover seems to have been machined a little small and there is rubbing around the outside diameter. I see no signs of the transmission having chewed anything. I disassembled the transmission shafts, the PV governor, checked shift forks and drum, every component of the clutch, kick start assembly, water pump, and every support bearing in it. I just can't find anything to explain those chunks.

Only odd things I have found is the output shaft inner bearing isn't seated completely in the case and I have just a small amount of movement side to side with the outer water pump shaft in the bearing but that could be within spec. Unless there is a part that just isn't there any more, even though I have scoured the parts diagrams to check, I just don't know what it could be.

No way those pieces could have been floating around in there since new and just finally found their way to the drain plug, right?
 
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