Tweet
Well, got around to tearing into Godzilla further.
Okay folks,
After breaking the left turn signal threaded stalk(hopefully I can unthread the remaining broken piece out and reuse the remainder to reinstall it?) I said I was going to HOIST it up like an almost endover wheelie! Well, I brought in the wooden hoist rig I had made the last summer from some 2x8 planks that used to be a bed frame, along with 2 layers across the top, and various 2x4 sections as cross braces to keep it from flexing and collapsing.
I put the bike lift under it, and pushed Godzilla up onto it, put it up on the center stand, and then skidded it up to the wheel stop end. This positioned the handlebars just underneath the hoist frame. I had first thought of using the EYE bolt I had rigged up, but then decided with the ratchet straps to just drap them across the top hoist frame piece....space them apart a bit and this along with attaching them to the handlebar clamps would help stabilize it some and keep it from spinning so easily!
Forgot to mention I pumped up the hoist to maximum height before attaching the ratchet straps, this way I didn't have to ratchet them much to get the height I was hoping for.
Then I LOWERED the lift to just clear the rear wheel, so essentially the bike was HANGING from the hoist/straps. I also attached 2 additional SAFETY straps to the frame and hoist since I was going to be sitting/laying UNDER the bike, and wanted something to keep it from crashing down on me if the handlebar clamps/bolts or the main ratchet straps gave way!
Dropped the oil pan, and pulled the OIL PUMP. I was surprised to see the condition of the O-ring. I had put a new one in in 2000 when I did my major topend/rebuild. I think I was from the LOCAL HARDWARE store, and I thought it was a NEOPRENE type that could withstand the oil and heat and pressure? Guess I was WRONG? I;m pretty sure it wasn't a Harbor Freight one though.
I was ready to remove the countershaft bearing but after 15 minutes searching realized that I had lost my 30T Torx bit I had used 17 years earlier, and had to run off to Lowes to get another one!
Got the shift pawl, and the shift fork shaft out, then pulled the 5th gear out, had already loosened and removed the large bolt from the other end of the countershaft, removed the shift forks, and then wiggled the shaft and gears and got it out in just a few minutes.
Here's what the dogs on the 4th gear that engages with the solid 6 land 1st gear looked like. No wonder it was starting to skip!
But now for the BIG REVEAL with regards to the 2nd gear and washer swap THEORY!!! Remember, folks felt that the extra thick washer doesn't allow enough depth engagement of the 5th gear dogs into the 2nd gear slots, and this is part of why we think they round off. Remember they are/were square cut at the factory! When I did my Tranny fix in 2000 and have put some 25+K miles on it, I did NOT do the washer swap. I just did an aggressive grinding of the 5th gear dogs and 2nd gear slots to match the same angles that WERE in the OEM 3rd gear dogs that WERE back/under cut at the factory.
SO..as you can see from these 2 photos, the dog on 2nd show essentially NO signs of rounding off on the tips/edges, and the simple step of undercutting the dogs and slots appears to be adequate alone for keeping them engaged and not letting them get rounded/worn which leads to skipping. The propensity for the rounding affect IMHO comes mostly from the OEM square cut design, and IF Yamaha had undercut/angle cut them at the factory, we wouldn't even need the Dremmel fix for the 2nd gear, much less the extra work of swapping/moving the washer, and then the extra work of trying to get the countershaft assembly back into the engine since the washer swap shifts things a bit more adding to the difficulty factor of this process.
I didn't TOUCH the 5th gear dogs/2nd gear slots at all this time, and STILL haven't moved the washer.
Here are the 4th gear dogs back/under cut a little more aggressively to match the 3rd gear dog angles, and I also reground the 6 lands/slots on the 1st gear trying to put a corresponding angle on them as well.
Then came the fun part of putting it together and back into the engine. The Countershaft assembly wasn't difficult, but the shift forks were a PITA! I got the middle fork flipped around the first time and THEN realized that the fork shaft wouldn't make it thru it and the 1st and 3rd shift fork. Had to reverse it, and and play with the shift drum and such, but finally got it all sorted out. Thankfully I had done this once before on it's BACk, I don't think I would still recommend this hoisting technique for the 1st timer/novice mechanic to use/attempt to perform this MOD/repair.
I got all of this done Friday night and Saturday afternoon early evening. Later that evening, SWMBO let me know that she had been having this "CHEST PAIN" off and on for several hours, and that it was radiating to her left arm and her neck! DING< DING...Warning Will Roger...DANGER...DANGER!!
Not sure how many of you all know that they(Medical community) has learned that WOMEN usually do not have these CLASSIC types of heart attack symptoms like MEN do, but these ARE classic heart attack symptoms. She wasn't nauseaus or sweaty, but knowing her strong family history of heart attacks....Dad-died, Sister, and Mother....She agreed that we should take her to the E.R. to be "checked out".
15-20 years ago she had some different chest pains, had a stress test and was diagnosed with Microvascular angina.....in other words, nothing to worry about THEN. She had also been given Nitro under the tongue, and all it did was give her a headache, didn't help the chest pain.
This time, they did a STAT EKG, drew cardiac enzymes/blood labs, and then gave her 4 kids aspirins, and then a NITRO. THIS TIME it helped the pain go away and didn't give her a headache....one confirmation sign! Her EKG and blood labs were OKAY, but because of her many other risk factors, diabetes, blood pressure, AGE, they said they wanted to ADMIT her to the Hospital for both observation and further testing ie. EchoCardiogram, eventually a Stress Test. So she spent the night, and today they repeated the cardiac enzymes/blood tests, and they still looked GOOD, she's been wearing a NITRO patch, and has not had any more chest pain. The EchoCardiogram appeared okay, but due to the Holiday weekend, the Cardiologist had already gone home for the day. The admitting Dr. discussed her case/history with him, and it was recommended that she stay yet another day/night for continued observation, and the Cardiologist will visit/see her tomorrow AM. Depending on his exam, they MAY let her go home tomorrow and get the additional tests on a OUTPATIENT basis. Not sure if she'll have to have a Cardiac Catheterization, and depending on those findings possibly a stent or so inserted IF they find significant blockage. But right now it looks like it was just an ANGINA attack, but not necessarily a full blown HEART ATTACK. PHEW!
So...here's hoping your holiday weekend is a bit more enjoyable than mine!
T.C.
Okay folks,
After breaking the left turn signal threaded stalk(hopefully I can unthread the remaining broken piece out and reuse the remainder to reinstall it?) I said I was going to HOIST it up like an almost endover wheelie! Well, I brought in the wooden hoist rig I had made the last summer from some 2x8 planks that used to be a bed frame, along with 2 layers across the top, and various 2x4 sections as cross braces to keep it from flexing and collapsing.
I put the bike lift under it, and pushed Godzilla up onto it, put it up on the center stand, and then skidded it up to the wheel stop end. This positioned the handlebars just underneath the hoist frame. I had first thought of using the EYE bolt I had rigged up, but then decided with the ratchet straps to just drap them across the top hoist frame piece....space them apart a bit and this along with attaching them to the handlebar clamps would help stabilize it some and keep it from spinning so easily!
Forgot to mention I pumped up the hoist to maximum height before attaching the ratchet straps, this way I didn't have to ratchet them much to get the height I was hoping for.
Then I LOWERED the lift to just clear the rear wheel, so essentially the bike was HANGING from the hoist/straps. I also attached 2 additional SAFETY straps to the frame and hoist since I was going to be sitting/laying UNDER the bike, and wanted something to keep it from crashing down on me if the handlebar clamps/bolts or the main ratchet straps gave way!
Dropped the oil pan, and pulled the OIL PUMP. I was surprised to see the condition of the O-ring. I had put a new one in in 2000 when I did my major topend/rebuild. I think I was from the LOCAL HARDWARE store, and I thought it was a NEOPRENE type that could withstand the oil and heat and pressure? Guess I was WRONG? I;m pretty sure it wasn't a Harbor Freight one though.
I was ready to remove the countershaft bearing but after 15 minutes searching realized that I had lost my 30T Torx bit I had used 17 years earlier, and had to run off to Lowes to get another one!
Got the shift pawl, and the shift fork shaft out, then pulled the 5th gear out, had already loosened and removed the large bolt from the other end of the countershaft, removed the shift forks, and then wiggled the shaft and gears and got it out in just a few minutes.
Here's what the dogs on the 4th gear that engages with the solid 6 land 1st gear looked like.
No wonder it was starting to skip! But now for the BIG REVEAL with regards to the 2nd gear and washer swap THEORY!!! Remember, folks felt that the extra thick washer doesn't allow enough depth engagement of the 5th gear dogs into the 2nd gear slots, and this is part of why we think they round off. Remember they are/were square cut at the factory! When I did my Tranny fix in 2000 and have put some 25+K miles on it, I did NOT do the washer swap. I just did an aggressive grinding of the 5th gear dogs and 2nd gear slots to match the same angles that WERE in the OEM 3rd gear dogs that WERE back/under cut at the factory.
SO..as you can see from these 2 photos, the dog on 2nd show essentially NO signs of rounding off on the tips/edges, and the simple step of undercutting the dogs and slots appears to be adequate alone for keeping them engaged and not letting them get rounded/worn which leads to skipping. The propensity for the rounding affect IMHO comes mostly from the OEM square cut design, and IF Yamaha had undercut/angle cut them at the factory, we wouldn't even need the Dremmel fix for the 2nd gear, much less the extra work of swapping/moving the washer, and then the extra work of trying to get the countershaft assembly back into the engine since the washer swap shifts things a bit more adding to the difficulty factor of this process.
I didn't TOUCH the 5th gear dogs/2nd gear slots at all this time, and STILL haven't moved the washer.
Here are the 4th gear dogs back/under cut a little more aggressively to match the 3rd gear dog angles, and I also reground the 6 lands/slots on the 1st gear trying to put a corresponding angle on them as well.
Then came the fun part of putting it together and back into the engine. The Countershaft assembly wasn't difficult, but the shift forks were a PITA! I got the middle fork flipped around the first time and THEN realized that the fork shaft wouldn't make it thru it and the 1st and 3rd shift fork. Had to reverse it, and and play with the shift drum and such, but finally got it all sorted out. Thankfully I had done this once before on it's BACk, I don't think I would still recommend this hoisting technique for the 1st timer/novice mechanic to use/attempt to perform this MOD/repair.
I got all of this done Friday night and Saturday afternoon early evening. Later that evening, SWMBO let me know that she had been having this "CHEST PAIN" off and on for several hours, and that it was radiating to her left arm and her neck!
DING< DING...Warning Will Roger...DANGER...DANGER!!Not sure how many of you all know that they(Medical community) has learned that WOMEN usually do not have these CLASSIC types of heart attack symptoms like MEN do, but these ARE classic heart attack symptoms. She wasn't nauseaus or sweaty, but knowing her strong family history of heart attacks....Dad-died, Sister, and Mother....She agreed that we should take her to the E.R. to be "checked out".
15-20 years ago she had some different chest pains, had a stress test and was diagnosed with Microvascular angina.....in other words, nothing to worry about THEN. She had also been given Nitro under the tongue, and all it did was give her a headache, didn't help the chest pain.
This time, they did a STAT EKG, drew cardiac enzymes/blood labs, and then gave her 4 kids aspirins, and then a NITRO. THIS TIME it helped the pain go away and didn't give her a headache....one confirmation sign! Her EKG and blood labs were OKAY, but because of her many other risk factors, diabetes, blood pressure, AGE, they said they wanted to ADMIT her to the Hospital for both observation and further testing ie. EchoCardiogram, eventually a Stress Test. So she spent the night, and today they repeated the cardiac enzymes/blood tests, and they still looked GOOD, she's been wearing a NITRO patch, and has not had any more chest pain. The EchoCardiogram appeared okay, but due to the Holiday weekend, the Cardiologist had already gone home for the day. The admitting Dr. discussed her case/history with him, and it was recommended that she stay yet another day/night for continued observation, and the Cardiologist will visit/see her tomorrow AM. Depending on his exam, they MAY let her go home tomorrow and get the additional tests on a OUTPATIENT basis. Not sure if she'll have to have a Cardiac Catheterization, and depending on those findings possibly a stent or so inserted IF they find significant blockage. But right now it looks like it was just an ANGINA attack, but not necessarily a full blown HEART ATTACK. PHEW!
So...here's hoping your holiday weekend is a bit more enjoyable than mine!
T.C.
.
Comment