loop frame engine out recomissioning

[lazlokovacs]

just checking - a light ticky takka ticky takka tiki tiki noise from the gearbox while wheeling the bike around in neutral is definitely not a good thing right?

I have the swingarm off currently so not too much work to get the box off, with the added bonus of shimming it all up a bit

my other question... fore/aft play in the u-joint on the torque rod and gb output spline is also not a good thing right?  The carrier bearing should hold the u-j in place (in the forward/backward axis) right?

and... third question!

Can I get the generator bracket out with the engine still in the frame or does it need to come right out? (could be a good time to do the bracket mod)

Heated garage, tools and time, lots of time!

Thanks guys

[acogoff]

     Being you have the swingarm off, I would turn the transmission with its output shaft and see if it is coming from the transmission. Same thing with the rear end. Noises can be bugger to find.

[Antietam Classic Cycle]

The transmission may not be completely in neutral or even the "real" neutral. Shift it up and down and back to neutral to be sure.

The u-joint should be a snug fit into the carrier bearing. One can use a punch to make rows of small indentations around the circumference of the u-joint to make it fit tighter or simply use a bearing retaining compound.

Yes, the generator bracket can be easily removed with the engine in the frame. Once the generator is off, you'll need to remove the oil line to the heads, and then the bracket.

[lazlokovacs]

acogoff - thanks.. I did that.. definitely coming from the gearbox

antietam - yep, I double triple quadruple checked real neutral


First nasty discovery of the strip down, the rear generator bracket bolt is indeed broken. Annoyed at that, as I wasn't planning on removing the engine from the frame. But pleased to find out now, rather than down the road somewhere. And I guess I can finally strip and repaint my crash bars which are looking a little sorry.

The broken bolt appears to be within an insert or a helicoil - will clean it up and figure out what I'm dealing with tomorrow.

Drill it out? (with great care!)




EDIT changed the title as I might as well post any pics and further questions here

[Antietam Classic Cycle]

First nasty discovery of the strip down, the rear generator bracket bolt is indeed broken. Annoyed at that, as I wasn't planning on removing the engine from the frame. But pleased to find out now, rather than down the road somewhere. And I guess I can finally strip and repaint my crash bars which are looking a little sorry.

The broken bolt appears to be within an insert or a helicoil - will clean it up and figure out what I'm dealing with tomorrow.

Drill it out? (with great care!)

I've never removed the engine from the frame just for a broken stud. Either used a right angle adapter and short (left twist) bits with my drill, or just welded a nut on the broken stud/built the stud up with weld.

[lazlokovacs]

good info... the one thing I don't do is weld!!

Maybe I can get a friend round to do it for me

[lazlokovacs]

I'll try and take a picture tomorrow if you'd be kind enough to let me know what you think

[Antietam Classic Cycle]

good info... the one thing I don't do is weld!!

Maybe I can get a friend round to do it for me

I don't either, well enough to trust anyway. Last one with a broken off stud, I loaded the Eldo into my Eurovan/T4 and hauled it to my friend that is a pro.

[jacksonracingcomau]

Re removing the box
To make it easy I removed the crankcase studs (double nutted)
With engine as far forward as possible gearbox now easily comes out or back in with swinging arm still in place
With swinging arm out you prob have loads of room anyway but if not this is simple way.
I replaced studs and nuts with bolts (except one on rh side) to make it easier next time

Clutch and gearbox actually easier to get to than tonti crab

[lazlokovacs]

this is what I'm dealing with here....

further tips gratefully accepted!!!

[Tom H]

Center punch the bolt and if you have one a left hand drill bit. Start with a small one.

Option.... Maybe you can get the helicoil to come out with the bolt. There is a tool to do it, the one I have won't work. Google it to see one. Maybe you can make something to work?

Good luck,
Tom

[Don G]

That is a ugly mess! Some people should not be let near a Helicoil kit  DonG

[lazlokovacs]

SO.. got the transmission open today.... everything appears to be quite well shimmed in there. Maybe my false neutrals were more of a product of slop in the linkages??

The  tiki taki tiki taka noise was the ball bearing from the speedo worm gear that had decided to take a walk! why and how I wonder...?

Bearings all look good, will probably just change the seals and put it all back together...