Author Topic: Help needed! I think I have just destroyed my gearbox!!! (Read 6991 times)

1967fazer · « **on:** 27 May 2012, 04:47:18 pm »

Been out for a ride today and on the way back I went to over take a van that was travelling really slow, 2nd gear, gave it some throttle and was passing said van when I hit a bump in the road and the front end came up, went to change in to third to bring it down and as I did it hit a false neutral, pulled the clutch in, clicked it up and it wouldn't engage properly! I managed somehow, to get passed the van and also manged to get a gear, but with a very nasty clattering/metallic noise coming from the 'box! As soon as I could, I pulled over. Now when its in neutral its clattering and when I pull the clutch in, the noise goes away. I can still get gears and drive to the rear wheel, but not with out nasty sounds coming from the box. Got a very nice man to ferry the bike home and will be taking it to the garage tomorrow.
The bikes done 32000 miles, its a gen 1 and it had plenty of oil in there.
Anyone got any clues? Am I looking at serious expense, which will probably mean the end of my summers biking or could it be something less scary? I'll be doing the work myself, so any help/advice will be helpful.
Help!

ghostbiker · « **Reply #1 on:** 27 May 2012, 04:51:53 pm »

hope its something simple, but thats the type of stuff i dont realy do.
maybe a selector fork?

Bracechenko · « **Reply #2 on:** 27 May 2012, 04:52:48 pm »

Could be clutch rather than gearbox mate, especially if the rattle disappears when the clutch lever is pulled in.

Someone with more knowledge will hopefully post soon but fingers crossed for ya!

Falcon 269 · « **Reply #3 on:** 27 May 2012, 05:28:25 pm »

Bad luck, that. Sounds like a bent selector fork, the occasional unfortunate outcome of a missed lower gear at high rpm.

Here's a couple of threads you might find useful (or scary, it depends... ):

http://www.yamahafz1oa.com/forum/showthread.php?t=119762

http://www.yamahafz1oa.com/forum/showthread.php?t=119101

Good luck!

ade the blade · « **Reply #4 on:** 27 May 2012, 05:49:44 pm »

sorry to say mate, but a mate had a cbf600 with `clutch issues`........long story short, clutch plates had seen better days but yes after stripping it down found a nice bent selector fork.

1967fazer · « **Reply #5 on:** 27 May 2012, 09:12:25 pm »

Thanks for the info guys, I had a feeling it was going to be a bastard to sort out! Don't suppose any one knows how much selector forks are?

devilsyam · « **Reply #6 on:** 27 May 2012, 09:26:37 pm »

pretty sure i have a lower engine assemb ly in the garage complete gearbox i'll have a look tomorrow if it helps was from a low millage cat b

1967fazer · « **Reply #7 on:** 27 May 2012, 10:29:44 pm »

Let me know DY, as the bike is going to the garage on Tuesday, ready for me to get real personal with my Fazer. Would be great opportunity to lose the AIS and get it Ivanised, but I'm going to struggle with paying for the all associated bits eg: gaskets, gearboxy bits and anything else I break along the way. Oh one other thing, once the motor is out, can it be turned upside down and cases split that way or do I have to dismantle everything? I have done a couple of gearboxes from old Gpzs and I will be getting hold of a workshop manual as well

AyJay · « **Reply #8 on:** 27 May 2012, 10:41:34 pm »

DON'T PANIC!

Ok, worst case scenario goes like this. Second gear, give it a handful, hit a bump, huge clattering sound from the gearbox. No drive in second.

That's what happened to me at 45000. I had the bike trailered back home, whipped the engine out and took the sump pan off. Second gear was missing a number of teeth. Now, about 10,000 miles earlier, I'd missed a gear on a track day and when it went back in, it made the most almighty bang and I'd always wondered what that did to the box. Turns out, it was probably knocking seven colours out of second gear. Having said that, it was always slipping out of second, and from what I hear Yamaha R1 gearboxes are also prone to this as well. Known problem.

I'll bet this isn't what you want hear .. . .

Anyway, stripping the whole thing down and replacing that one gear was way more expensive that getting a second hand engine unit, so that's what I did. Took a couple of days to swap the two units, but this replacement has never slipped out of gear and I'm up at 91,000 miles now. I see on eBay tonight, there's one for £330. Way cheaper than getting dealer to strip the engine.

I hope it's not as serious as this. I really do, but if it is, don't panic, it can be rectified.

1967fazer · « **Reply #9 on:** 27 May 2012, 11:43:13 pm »

Thanks for that thought, however, it'll be me stripping the box etc down and putting it back together (hopefully correctly), should save me a small fortune in labour charges, which is good as I'm a tad skint just now.

devilsyam · « **Reply #10 on:** 28 May 2012, 08:52:49 am »

when i had nitro on the bike i bought this for a spare in case the box went bang with the extra oummmph but it didnt
came from a cat b write off box is mint

£150 which is what i paid for it and you get wot's in the picture motor wise
im in bristol and you got till the 5th or after the 19th to collect as away on epic usa tour
postage will be stupid as on me fishing scales over the 50kg limit it goes up to so god know the weight

luke

1967fazer · « **Reply #11 on:** 30 May 2012, 10:27:11 am »

Cheers for that Luke, might yet have to take you up on that, tho how I'll get it up here I don't know. Got the bike at the garage now, so will attempting the assualt on it shortly. It'll probably be after you get back from your jollies, if I need the 'box. I'm going to start with the clutch, as that will have to be removed anyway and then move on to the main course.
At least it'll give me chance to clean up all those bits that rarely see the light of day!
Just wish it had happened at the end of the season!
Enjoy your holiday Luke:-)

1967fazer · « **Reply #12 on:** 24 June 2012, 11:41:00 pm »

So whipped the engine out and took it a mate who work at a bike garage and said he'd do it on the side. He took the sump off on Saturday and apparently lots of metal lumps fell out!!! Bugger!
Devilsyam, will be getting in touch with you, regards your spare 'box, just got to sort some funds first!

devilsyam · « **Reply #13 on:** 24 June 2012, 11:44:00 pm »

yeah when ya ready found the pistons to match the barrels too so will inc them

1967fazer · « **Reply #14 on:** 25 June 2012, 01:41:22 pm »

Quote from: devilsyam on 24 June 2012, 11:44:00 pm

yeah when ya ready found the pistons to match the barrels too so will inc them

PM sent (hopefully)

devilsyam · « **Reply #15 on:** 25 June 2012, 11:29:49 pm »

yep got it

1967fazer · « **Reply #16 on:** 28 July 2012, 11:52:46 pm »

Finally after two months, my bike is finally back on the road, complete with almost new gearbox

. Hopefully, I won't have anymore trouble for a while and get chance to enjoy the bike again. My thanks must go to Luke (Devilsyam) for supplying the almost new gearbox at a very decent price, Nige at Appleyards in Leeds for doing the 'box swap in his spare time and my boss for letting me use his workshop facilities (and his expertise). Roll on summer (mkII)...

ghostbiker · « **Reply #17 on:** 29 July 2012, 12:36:03 am »

grats, just in time for the onset of more weeks of rain

devilsyam · « **Reply #18 on:** 29 July 2012, 11:38:00 am »

good news did ya use just the box or the full monty

1967fazer · « **Reply #19 on:** 29 July 2012, 09:50:04 pm »

Hi Luke, just used the gearbox internals, still got the pistons and case. Took the beastie out for a blast today, all went well apart from it not revving out.....think I might need to re adjust the exup cables!