Gearbox bearings ??

[KiwiKev]

Hi guys, my Cali 1100i has been slipping her clutch for some time now. I pulled her apart before xmas but only removed the input spline last weekend with my older bro's help.

Made up a tool from an old socket as Roy suggested but it broke first time. Made another one using the same socket and got the bsturd off.

Clearly the bearing is stuffed as well, plastic cage fell apart and chewed out the oil seal. Got that out without much trouble, I'm guessing that the output bearing is made of the same stuff so would be wise to replace that too.

Clutch plates have plenty of meat on them - what are your thoughts about replacing these as well now I have her in bits.

I'm sure there are many gearbox related topics but I haven't found a search function on my iPhone using tapatalk

Thanks in advance

Kevin


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[KiwiKev]

Oh yeh is it normal for the end of the main shaft to be bell shaped as in my
Pic ?


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[pete roper]

Yes the shaft should look like that.

The ATN9 bearings aren't really up to the job. You need 3205AC3's. If you can't find them locally let me know this week and I'll bring a pair with me. I'm on my way to NZ next Saturday.

Pete

[Chuck in Indiana]

Bring your wallet when you meet up with Pete.  Those suckers are expensive.

[Wayne Orwig]

Yes, replace both bearings.
Replace the plates. It slipping, that may have gotten oiled. I have encountered oil traveling up the clutch pushrod contaminating the plate, often. So replace the pushrod seals also.
I always put a normal nut back on the input shaft to replace that pegged nut.

[Antietam Classic Cycle]

Yes, replace both bearings.
Replace the plates. It slipping, that may have gotten oiled. I have encountered oil traveling up the clutch pushrod contaminating the plate, often. So replace the pushrod seals also.
I always put a normal nut back on the input shaft to replace that pegged nut.

This^^^. I'll add: replace the plates with ones with a solid center, not "spoked". I like the SD-TEC plates from MG Cycle.

I'll send you a set of six o-rings for the clutch pushrod for free cost of postage, just PM me your address.

[KiwiKev]

Hi guys,

Thanks for the advice and offers of help.

Yep most of the gearbox oil had decided it likes life better on the outside.

Luckily I caught it before it all escaped.

My bro kiwi Roy sent me a bunch of seals he had left over from his various kits. I think there are some seals for the pushrods amongst that lot.

I'm lying in bed feeling sorry for myself with a cold. It's only six am here so will catch a few more zeds before trying to slip in some quality time with my Italian gf during the day

Cheers

Kevin


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[KiwiKev]

Yes the shaft should look like that.

The ATN9 bearings aren't really up to the job. You need 3205AC3's. If you can't find them locally let me know this week and I'll bring a pair with me. I'm on my way to NZ next Saturday.

Pete

Hi Pete,

Wow thanks a bunch for your kind offer. We live in Taupo but have friends in Akl who are coming down here in a week or so.

If you're coming this way let me know and we'll put you up for a night or three.

You can fix her up in return - lol.

Kev

I asked mr google to find those bearings and he wasn't that helpful Found the same number with an X suffix that's all.


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[Peter949]

Hello ... I would like to ask the group if the gearbox bearings with the 'plastic' cages are prone to early failure?     Presently my 04 Cali EV has about 35,000 kilometers, and should it be updated with the steel caged bearing suggested by Pete to prevent a roadside failure?

Also I have read that the plastic caged bearings do not do well with synthetic oil.

Cheers,   Peter

[KiwiKev]

Well my speedo is showing 66836 so make of that what you may. Plenty of wiser heads than mine here though.

1997   CAli 1100i, been my ride to work and back for approx three years. 25 - 35 mins each way come rain or shine.

Stopped on me twice during that time, out of gas once on the way to work - DOH.  Other time she just cut out- connector on the ECU half off so that was a roadside fix.

 Gearbox bearings are another kettle of fish, I'll heed the advice of wiser heads here.



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[Chuck in Indiana]

Hello ... I would like to ask the group if the gearbox bearings with the 'plastic' cages are prone to early failure?     Presently my 04 Cali EV has about 35,000 kilometers, and should it be updated with the steel caged bearing suggested by Pete to prevent a roadside failure?

Also I have read that the plastic caged bearings do not do well with synthetic oil.

Cheers,   Peter

Hi, Peter.. I wouldn't overly worry myself about that. I don't remember of the 04 has the plastic caged bearings or not.. I'm old..  but. I put 42000 miles on my Centauro with nothing but Mobil 1 in the drivetrain. I've heard of higher mileages with syn and the plastic caged bearings. For sure the Centauro had them. If you are concerned, just run dino oil. How hard is that? 

[pete roper]

The problem with the 'Plastic Caged' ATN9 bearings is that with only 9 bearings in each race, especially on the very tall geared Calis, the shock loadings eventually destroy the cages. The 3205-AC3 type have 14 balls per race and a serpentine cage with a filling slot. They are substantially more robust and failures, even at very high mileages, are rare. These were factory fitment in all five speeds up until the mid eighties. The only reason I can think they were changed was cost as the AC3's are slightly more expensive than the ATN9's.

[KiwiKev]

Well, new bearings arrived  - thanks Pete. Now I have to pull finger and put all the bits back together that are strewn around my garage.




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[KiwiKev]

https://flic.kr/p/SLtgu5
https://flic.kr/p/RA7bQn
https://flic.kr/p/Sffo2y


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