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Post by steve63 on May 17, 2021 13:05:22 GMT 1
While you seem to be in the mood for 4 stroke engine problems I thought I'd offer up another for you to put your brain around About ten years ago I had a odd problem with my 99 R1 which I thought was the clutch. It would slip sometimes and then drag at others. I couldn't seem to make it consistent. Then it started making a horrendous noise as if something drastic had gone wrong somewhere in the bottom end. When I stripped it some of the gears were literally black and blue. The oil is fed under pressure to the (main?) shaft that the clutch fastens to, a washer in the end inside the clutch means that the oil then is forced out through a series of holes in the shaft and runs down into the gearbox. The washer on mine was laying in the clutch which meant the oil was just filling the clutch and not lubricating the gearbox. After fixing the issue and rebuilding the bike with Ā£600 of bits I had about 15,000 trouble free miles out of it until I noticed one day it kind of (for want of a better word) jerked as if something was slipping. This wasn't like a clutch slip but felt more mechanical as if something that should be an interference fit was slipping. It did it a couple of times and every time after a bit of a spirited ride and so briefly I tried to convince myself that I imagined it until one day after a good hammering down a straight that it started doing it all the time. I've convinced myself it's an engine out job so the bikes been sat in the garage for nearly two years waiting for the day when I can bring myself to have a look. Anyone like to give it a guess as to what it might be?
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Post by julianboolean on May 17, 2021 13:49:48 GMT 1
Worn out chain and sprockets
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Post by steve63 on May 17, 2021 18:03:56 GMT 1
Worn out chain and sprockets You may smile but I actually tried to convince myself it was the chain jumping a tooth or two. I changed the chain and sprockets but inside I knew it wasn't that. It does actually feel more like that kind of thing than a smooth clutch type slip š
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Post by beardy on May 17, 2021 20:56:32 GMT 1
Any particular gear? Iām thinking dogs on the gears. 2nd is quite common.
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Post by beardy on May 17, 2021 20:58:48 GMT 1
Had it happen on my old zzr600. Was able to turn the engine upside down and take the bottom half of the crankcase off and fix without disturbing the top end.
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Post by steve63 on May 17, 2021 22:52:13 GMT 1
Any particular gear? Iām thinking dogs on the gears. 2nd is quite common. That's the thing, it seemed to be in any gear. It was doing it in gear with the clutch in. I started it up a couple of months ago and warmed it up. I was only riding it a few yards and pushing it back but there was no sign of the issue. It was the dogs and the slots they go into last time. I think 2nd was the worst but I replaced a few of them. It feels like something different this time. It sort of slips and re-engages in an instant and only seemed to do it when the engine was very hot after a bit of a hammering. There's no grinding of gears like before. Almost like something with an interference fit is letting go. I'm just going to have to bite the bullet and get it done. I was asked if I wanted to sell it as it is but I've had it nearly 20 years so I can't do it.
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Post by steve63 on May 17, 2021 23:01:49 GMT 1
Had it happen on my old zzr600. Was able to turn the engine upside down and take the bottom half of the crankcase off and fix without disturbing the top end. Yep, I turned it over and stripped the gearbox out. The Haynes manual says the top end has to be removed but it doesn't. It turned out it had been stripped before, probably to do the 2nd gear. I found a couple of set screws in the sump that had come undone, single use screws that had been used again including a torque bolt and the baffle plate that the screws were supposed to hold in place also In the sump. Not surprising to me but it would be to some people it had been done at a local motorcycle repair dealer by a "professional" motorcycle mechanic.
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Post by julianboolean on May 18, 2021 13:36:03 GMT 1
Sounds like a seriously shagged clutch, you might as well take the casing off and have a look, it's got to come apart anyway.
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Post by midlifecrisisrd on May 18, 2021 20:18:14 GMT 1
If it's doing it in all gears it can only be the clutch or primary drive
Is an R1 gear or hivo chain driven
If chain it could be jumping
Steve
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Post by midlifecrisisrd on May 18, 2021 20:23:40 GMT 1
May be nonsense but I just saw this online Steve
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Post by steve63 on May 18, 2021 21:57:13 GMT 1
If it's doing it in all gears it can only be the clutch or primary drive Is an R1 gear or hivo chain driven If chain it could be jumping Steve It's a gear cut into one of the crank webs that drives the back of the clutch. I actually bought a second hand clutch when the problems started the first time but when I took the cover off I couldn't see anything at all amiss with the original. Even buying the clutch wasn't without problems. The courier damaged the basket, broke a tang off. The guy refunded my money. Then a basket popped up on eBay for next to nothing so I bought it so I do have a spare.
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Post by steve63 on May 18, 2021 22:06:49 GMT 1
May be nonsense but I just saw this online Steve That's something to look forward to š Hopefully it's not that, mine is a 1999 model but registered in 2000. It's exactly the same as the much sought after first model red and white with an orange seat model but a different colour, red and white with a black seat and (hopefully) the recall mods all done. It's got to be the drive on the back of the clutch they are talking about. I'll have a closer look. I do feel like stripping it is getting close. I'm just reluctant to have yet another bike in bits. On the other hand I haven't got a working bike at the moment and I'm getting those urges to ride again. So much so I messaged a guy about a ZZR11 and I've been looking at a VFR800. I probably need help š„“
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Post by steve63 on May 18, 2021 22:21:17 GMT 1
Breaking news, I've just had my offer accepted and bought myself a used R1 gearbox. It could easily be as knackered as mine I suppose but fortune favours the stupid or something like that š¤
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Post by steve63 on May 19, 2021 22:09:29 GMT 1
I've fixed the lack of a working bike problem tonight by buying a VFR800.
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Post by steve63 on Jun 9, 2021 21:42:13 GMT 1
Today I went up to Bridlington for some fish and chips. When I arrived home I had an idea. Book the R1 in for an MOT, that way I could legally ride it to the MOT station and try to get an exact feel for what the problem is. I went a bit of a long way around to the MOT and you know what? Nothing wrong with it š„“ Instead of coming straight home I took the long route and did maybe 10/15 miles. The last few miles were the exact same route as I'd ridden a couple of hours earlier on the VFR. That was quite an eye opener. I'd actually forgotten what an awesome bike it is. The gearbox thing has got to be something to do with riding it hard and it getting really hot. There is a 1 mile straight on my way home. About halfway down there is a junction but after that you can give it a bit. At the end there is a 70/80 mph corner (if it was a track) just after that corner was the first time it did it and I thought I'd imagined it.
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