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I was out for a ride a few weekends ago when I heard a gawd awful racket form around the transmission. Stopped and found when in neutral but when on centre stand in gear it wasn't pretty. So spent $400 on getting a truck ride back home (approx 80 miles)
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Did some thread searching and concluded it was likely the bevel gears at the shaft to gearbox union and had a read up on it.
As luck would have it, I had the spares needed from the parts bike that came with the original bike purchase. (Since stripped right down to parts).
I concluded that there was no way that I had the confidence, skills, tools or patience for the job so set about finding someone who could do the job. None of the bike shops were keen so I settled on a mobile mechanic who comes highly recommended.
He arrived last week and spent a couple of hours sizing the job up and was initially pessimistic and suggested the that the engine would need to come out be pulled down and rebuilt and that it would cost thousands. He was very surprised that I had the needed parts and I gave him a print out of all of the thread info which I had found in my search. He had a read then decided that maybe it was something that could be done. the following week.
Yesterday he arrived and managed to pull the wheel and swing arm off then demount the engine. I bought some work home to do (so I could earn $ to pay him). He found the bolt connecting the shaft to the bevel gear assy had sheared and that subsequently the free movement had resulted in the bevel gears eating each other out. He/we had a pig of a time getting the side mounted bevel gear out (after the shaft bevel assy was removed). Even loosening the case bolts it took about 2 hours of levering and driving to get the sucker out. The side mounted bevel gear was severely munted (see photos).
He gave the housing a good rag clean and started reassembly. I raised the issue of backlash and he responded that he was confident that the existing shims would be ok (as the serial number of the motor the replacement gears came from was sequential to that of motor in this one).
He got it all back together just on dark then started it and ran it in gear on the centre stand and it sounded ok. Then he took it for a test run just before the rain came down and pronounced that she was all good to go and gave me a bill for $760 (paid).
I started her up on centre stand and popped her in gear this morning and can hear some worrying clacking noise. I videoed and up loaded to the link below (along with a couple of pics of the munted gears) I suspect that some of the damage to the bevel gear was as a result of the beating it took while I was levering and he was driving it out with a hammer and long steel rod.
Can I please have your opinions on the noise and whether I should ride her or strip her down and set the backlash properly.
.Did some thread searching and concluded it was likely the bevel gears at the shaft to gearbox union and had a read up on it.
As luck would have it, I had the spares needed from the parts bike that came with the original bike purchase. (Since stripped right down to parts).
I concluded that there was no way that I had the confidence, skills, tools or patience for the job so set about finding someone who could do the job. None of the bike shops were keen so I settled on a mobile mechanic who comes highly recommended.
He arrived last week and spent a couple of hours sizing the job up and was initially pessimistic and suggested the that the engine would need to come out be pulled down and rebuilt and that it would cost thousands. He was very surprised that I had the needed parts and I gave him a print out of all of the thread info which I had found in my search. He had a read then decided that maybe it was something that could be done. the following week.
Yesterday he arrived and managed to pull the wheel and swing arm off then demount the engine. I bought some work home to do (so I could earn $ to pay him). He found the bolt connecting the shaft to the bevel gear assy had sheared and that subsequently the free movement had resulted in the bevel gears eating each other out. He/we had a pig of a time getting the side mounted bevel gear out (after the shaft bevel assy was removed). Even loosening the case bolts it took about 2 hours of levering and driving to get the sucker out. The side mounted bevel gear was severely munted (see photos).
He gave the housing a good rag clean and started reassembly. I raised the issue of backlash and he responded that he was confident that the existing shims would be ok (as the serial number of the motor the replacement gears came from was sequential to that of motor in this one).
He got it all back together just on dark then started it and ran it in gear on the centre stand and it sounded ok. Then he took it for a test run just before the rain came down and pronounced that she was all good to go and gave me a bill for $760 (paid).
I started her up on centre stand and popped her in gear this morning and can hear some worrying clacking noise. I videoed and up loaded to the link below (along with a couple of pics of the munted gears) I suspect that some of the damage to the bevel gear was as a result of the beating it took while I was levering and he was driving it out with a hammer and long steel rod.
Can I please have your opinions on the noise and whether I should ride her or strip her down and set the backlash properly.
. Told me off big time for running it in gear on the centre stand (even though he did that himself last night before taking it for a test ride 
I see. That isn't a pretty solution either 
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