'99 R1 Gearbox Rebuild

[Fortuna]

Hi.
Early R1's suffer from the dogs wearing out extremely quickly which causes them to jump out of 2nd gear when under power. Not only does it jump out but it causes damage to other components as well.
I'm surprised mine hasn't gone earlier to be honest as it's done 20,000 miles and I used to go up to London on it regularly.

Here's the engine with the bottom case removed. You have to remove all cases,oil pump,clutch and sump.
This is the only way to remove the gearbox. The engine is worked on upside down. No gasket is used between the cases either!
https://www.spyderman.pwp.blueyonder.co.uk/images/BikePics/DSCF0050.JPG

https://www.spyderman.pwp.blueyonder.co.uk/images/BikePics/DSCF0051.JPG

Damage to the selector fork.

https://www.spyderman.pwp.blueyonder.co.uk/images/BikePics/DSCF0047.JPG

Damage to the guide in the selector drum.

https://www.spyderman.pwp.blueyonder.co.uk/images/BikePics/DSCF0048.JPG

Drive for 2nd comes from engaging with 6th. Here's the damage to the dogs on 6th. Notice the 45º chamfer on the left side of the dog.

https://www.spyderman.pwp.blueyonder.co.uk/images/BikePics/DSCF0054.JPG

https://www.spyderman.pwp.blueyonder.co.uk/images/BikePics/DSCF0055.JPG

https://www.spyderman.pwp.blueyonder.co.uk/images/BikePics/DSCF0053.JPG

And finally the damge to the engagement holes on 2nd.

https://www.spyderman.pwp.blueyonder.co.uk/images/BikePics/DSCF0052.JPG

One thing that was surprisingly easy was getting the engine out of the frame.
The new parts have 5 dogs as opposed to 3 and a slight undercut to prevent this happening again. I'll do a side by side when the new bits arrive.

[Handsome]

Therein lies the problem and answer, if it'd been a '98 R1 Chuck Norris would have been round and done it for you...

Fairplay though as for me to attempt something like that I'd have needed two weeks to think about it, another week to stand there looking at it scratching my arse, then when I attempted it, copius amounts of tea and cigarettes...
____________________
Previous Bikes...Honda NSR 125 RR...Kawasaki Zephyr 550...Suzuki SV 1000 S...Yamaha FZ8...Current Bike...Suzuki GSX-R 750...

[Fortuna]

[Frost]

Bloody hell that looks an arse to work on!

I'm not surprised litre bikes do that to the lower gears of bikes with the amount of power they have. Last time i bought some gears they were about £45 per cog, the selector fork shouldnt be quite so bad, but that barrel is going to be expensive me thinks. Problem is that a 2nd hand gearbox might be in just as bad condition.

Cheaper than getting a new bike, or getting a mechanic to do it though i suppose. Once its done you will at least be safe in the knowlege that its not going to need doing again.

[Fortuna]

[Irezumi aka Reuben]

[400bandit]

Yamabond I take it? Can't remeber the code for it but it's supposed to wicked stuff.

Joe
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Current Bikes 650 Honda Bros, VTR1000 Firestorm // Past Bikes: Sachs Madass 50/110cc - Bandit 400 - FZR750
(+ a XS650 in lots of pieces in my garage and other places...)

[Fortuna]

[sloppy2ndgear]

[quote="Fortuna"
The new parts have 5 dogs as opposed to 3 and a slight undercut to prevent this happening again. I'll do a side by side when the new bits arrive.[/quote]

Hi mate i hope you see this and reply because i am in need of your help. I just have one simple question that no1 can answer for me except you it seems lol. When you ordered the 5dog instead of 3dog gears, did you order the part number on the 5jj parts manual and the 5 dogs came instead of 3 dogs or was there a completely different part number that you used?

Will love you forever if you can remember!

Thanks in advance!

[Iain.]

Threads nearly six years old & he's not been on here since 08 Jan 2014...

[c_dug]

Might be worth dropping him a PM, some people get an email notification when a PM arrives.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[sloppy2ndgear]