Crankcase problem...

[the108penguins]

as far as I know the 2nd gear fix has been done. The friend I bought it off of said that the owner before him had a machinist do it for him. is there any way I can see if it has been done with out taking too much out?

[CatatonicBug]

Depends on what you consider "too much". The gear that is closest to the left side of the bike will fall out if the shaft bearing is removed (3 torx screws behind the shift pawl). You should be able to tell if the dogs on that gear have been cut down without taking the whole shaft out. It just slides back into place, and the bearing slides back in over it.

[motoman]

You might be able to tell from underside looking up and possibly tell if the "dogs" were somewhat backcut(dovetailed) ever so slightly or just taken down so as to have a squared edge on them using a flashlight. If they were machined, may be hard to tell. Pretty much if the "dogs" that engage into slots are not rounded off on the edge, may be okay. Sure would save some extra work if they looked good!

[3Phase]

I've taken the left side cover off and lo and behold the pin is from a sprocket thingy that allows you to shift. I didn't notice any shift problems because this is the pin for 5th gear and it just never got there

...

plus the star washer holding them in is finished so I'll need a new one of those.

Boo-jah! He's found the pin!

Okay, I've got a spare gear oil pump drive gear you can have but I'm fresh out of starfish washers. I think you can still buy them new, that'd be the best.

From www.boats.net: 2H7-18561-00-00 || PLATE, SIDE 1 || $7.94


Regards,

Scott

[motoman]

Washer can still be got from dealer, part #2H7-18561-00. That no. is right off the packaged one I have for an extra. Pins too are still available. Washer is about $4, can't remember what cost of pins are. Seem to remember a pocket full of chage will cover a couple of those.

[turbo3g]

Dude how is the bike coming along? :P

[the108penguins]

pretty good I've been out of town so I haven't got a chance to check the gears yet but as soon as I get the parts and conformation of the 2nd gear fix, it i'll be running. nice pics of it though. when did you take those?

[the108penguins]

back from a nice vacation in panama beach, and i popped under the bike to see if i could tell if the 2nd gear fix had been done. well... it doesn't look like it so I guess I'll have to get it done now.

[motoman]

penguin, if I may, would also highly reccomend not re-using any snap-ring that has come off other than having been actually removed with snap ring pliers.

[the108penguins]

I'm going to try and drop one of the gears to see if the the 2nd gear fix has been done. I'm about to take the plate off that's under the shift lever (the one held on by the three loc-tit'ed torx screws) and it looks like someone ellse has already been at it and stripped out the heads what's the best way to get them out now? I'm going to try and extract them but I'm wondering if you guy's have any tips on other stuff to make it easier.

[CatatonicBug]

I've had that same problem on 2 bikes. An impact driver (the kind you hit with a hammer) sometimes works. However, I usually just drill the heads off, and that leaves enough of the threads sticking out after you pull the cover off to grab the bolts with some vise-grips and spin them out. I've replaced them all with phillips head screws from Home Depot.

[motoman]

Bummer....PO's work(or lack of correctly done) can make things difficult. If you have a 3/8" corrct size torx, might try using a hand-held impact. Torx may hold in slots good enough along with the "shock" to release the screws. Nothin' to loose and worth the try first before resorting to drastic measures.

[the108penguins]

so I ended up removing the shaft bearing but it's toast (it was a nasty battle but those three ba$&@rds are out now and my engine case is fine, only one small nik and I think she'll live) so I'll need a new one. looks like I'm going to need a few parts now so I think I'll place a bulk order with andreas if he's got em.

[3Phase]

Did you get the gear I sent to you or did another 108penguins in Florida wind up with it?


Regards,

Scott

[the108penguins]

Yea I got the gear, thanks man. looks brand new. I'm waiting on a few more parts now before she'll be ready to ride