ChrisGamlin
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| posted on 29/8/07 at 10:00 PM |
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Death of a gearbox
As a couple of you know, I had a "minor" gearbox issue with my 2003 R1 at the BaT Spa trackday last week, as can be heard from the onboard
footage here:
YouTube Vid
It seemed fine going 1st to 4tup through the box on the straight but made an alightly clatter going back down into 5th at the top of the straight,
then subsequently jammed in 4th. Initially I had vague hopes that it was simply due to a loose bolt in the linkage that I found, but the noise
suggested otherwise and so it proved as it was no better after tightening it up and I missed a day and a half track time on one of the best circuits
in Europe 
Firstly I dropped the sump and found all these which wasnt promising!
I then took the engine out this weekend to split the block and get the gearbox out but got stuck trying to get the stator / alternator drum off the
end of the crank. The workshop manual mentions a Yamaha tool to wind it off but without that, I tried a couple of other ways having found the correct
thread to use mentioned on an R1 forum. I bolted the engine to the bench to stop it moving and bought a suitable bolt (M16 x 1.5 for future reference)
to impact drive it off but it never moved, and I still couldnt get it to budge with a breaker bar on the bolt before it started stripping the threads
on the bolt(!), so in the end I bought a high tensile 12.9 bolt and made up this
"tool" with an axle stand sitting under the smaller bolt to support it and stop everything twisting (which contributed to the first
bolt stripping I think), along with chocks inside the engine to stop the crank turning. Suffice to say its not a job Id want to do every day but it
did the job in the end and with the help of a 3ft length of scaffold pole put over the "tool" to add some leverage, the stator finally
popped off.
...and after Id split the block and got the gearbox shafts out, all was revealed....
This is 5th gear on the input shaft sans all of its dogs, which is the gear that I was selecting when it all went wrong at the top of the Kemmel
straight in the vid. At least I did it properly though, no nancy rounding off of dogs, I managed to break them all clean off!
Everything else looks OK though apart from the adjoining gear of course, and possibly the forks which may be bent (not checked yet). I think i can
count myself lucky that none of those bits found their way into the remaining working area of the gearbox which would have caused a lot more mess and
could have locked it solid at about 100mph, which would have been interesting!
Anyway, I have a friend who has a spare gearbox so hopefully shouldnt be too long before its all back on the road!
Chris
[Edited on 30/8/07 by ChrisGamlin]
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tks
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| posted on 29/8/07 at 10:46 PM |
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Woow!!
Looks like chain reaction then, peeling them off as it just whas made from cheese!
You now now wy you lost 5th gear but you don't know wy it went? or do you think a small haircrack on that pinion went bigger and bigger
etc....??
The above comments are always meant to be from the above persons perspective.
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jollygreengiant
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| posted on 30/8/07 at 04:09 AM |
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Don't need to watch the vid to know the noise. Lovely isn't it. I did something similar about 24 years ago. I had a mk1 cortina with a
single rail box out of a mk2 cortina hung on the back of £1.5k (modern value about £96K ) worth of race built Xflow. Did a traffic light start one
day and there was an almighty bang. Limped it home 4.5 miles and then the box locked up totally.
When I stripped it I found I had stripped ALL the teeth off of the input shaft.
Hope you get back on the road soon mate.
Beware of the Goldfish in the tulip mines. The ONLY defence against them is smoking peanut butter sandwiches.
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02GF74
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| posted on 30/8/07 at 11:10 AM |
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JB Weld?
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Hellfire
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| posted on 30/8/07 at 11:16 AM |
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Chris, sorry to hear that, Are you gonna fit a TRT now? 
Only kidding (sort of).
Did you notice if the rear wheels locked on your change down from 6th to 5th and could the impact of this have caused it?
Phil
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smart51
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| posted on 30/8/07 at 11:31 AM |
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Bad news. You did it properly though didn't you? Are you sure there is no secondary damage from all the debris?
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ChrisGamlin
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| posted on 30/8/07 at 12:04 PM |
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Hi Phil
Nope the rears didnt lock, I wasnt even particularly "on it" at that time as it was still damp and there was a slower car in front of me
so I lifted quite a way before changing down. Im generally fairly sympathetic when changing down anyway, Im not one for buzzing down a gear the second
there's available revs and loading it up too much, I generally do most of my braking first then shift down a few gears in quick succession at
lower revs before turning in.
I may fit a TRT at some point though, I certainly don't disagree that they offer a benefit but I dont think it had a lot to do with this failure
TBH.
smart51 - there may be some secondary damage yep, I haven't had time to take all the gears off and inspect them properly yet but on initial
inspection there doesnt appear to be a lot else wrong, so fingers crossed.
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coozer
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| posted on 30/8/07 at 02:34 PM |
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Hmm.. it seems horror stories like this are getting more regular...
Take my advise, put a nice car engine in....
(Back behind the flack curtain):-)
1972 V8 Jago
1980 Z750
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BenB
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| posted on 30/8/07 at 03:50 PM |
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quote:
Originally posted by 02GF74
JB Weld?
ROTFL!!!!!
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ChrisGamlin
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| posted on 30/8/07 at 05:28 PM |
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quote:
Originally posted by 02GF74
JB Weld?
Its "stronger than the metal itself"* IIRC, so why not!
* Or was that a wood glue of some description?
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