THe most God-forsaken noise on my new bike!

[CA]

Think I found it...

Think I have identified the source of the noise, just don't know exactly what it is and how to fix it. You can see/hear it most clearly from looking into the crankcase and it is the smaller circle of ball bearings behind the clutch. It seems to be the source of the noise. I am sure I real engine speed it gets pretty nasty. Just need to know what and how to fix this!

A few facts:
PO did the 2nd gear fix
There was a a glittering of metal flakes at the very bottom of the oil pan.
36k on the bike.
The few miles I rode it, it seemed to shift very well.

Here are a few videos that will show what I am referring to hopefully.

http://www.youtube.com/watch?v=xx7YbFotCak

http://www.youtube.com/watch?v=3egUga7_pOQ

Thanks for your help!

[petejw]

bit hard to tell by the vid,
its not the gear on the left (middle drive) hitting the
top of the fork guide?
the guide has a notch in it, if its not seated
properly it can make a noise siilar to yours.

[CA]

Maybe a picture..

Thanks pete, it is hard to tell as a novice when you are in there....ha. From our observation it seems to originate from the thing in the picture to which the BLUE arrow is pointing to.



There are ball bearing things in there (I know still learning) that when rotated do not turn smoothly, not seated properly. When you put your finger on it, you feel a good deal of movement, vibration like they are not being held in properly or something.

Now this may be a symptom of something else, but it definitely doesn't sound right.

Any good diagnoses?

[DGXSER]

IT sounds very much like a gear noise, as in the spacing of the sounds seems like gear teeth hittign something they should not be.

The blue arrow points to the bolt and bearing that the countershaft rides on. When performing the second gear repair, that bolt is pulled and the chaft of gears you were looking up at comes out by pulling the shaft behind that bolt out of that bearing.

If it were me, I'd pull the clutch basket off like in that picture and see if you can still hear it or better locate the source. I am almost thinking perhaps the PO did not get the circlip on the oil pump idler gear correctly and it might be wandering on the shaft causing issues.

[CA]

Dgxser

I see what you are saying. A vibration/noise from that bolt/bearing could be any of the gears not seating properly or something. Gotcha, makes sense.

I will pull the clutch basket off either today or tomorrow and see what I can find. Will the oil pump gear be inside the transmission or on the side of the crankcase. Just wandering what I should be looking for with that circlip.

Looks like he didn't quite do the 2nd gear fix quite so well. He also mentioned that he moved the washer, I remember reading about that. Not sure if that helps....

Thanks

[CatatonicBug]

Will the oil pump gear be inside the transmission or on the side of the crankcase. Just wandering what I should be looking for with that circlip.

Looks like he didn't quite do the 2nd gear fix quite so well. He also mentioned that he moved the washer, I remember reading about that. Not sure if that helps....

The Oil pump Idle gear is in that picture. Its the gear being pointed at by the furthest LEFT red arrow pointing DOWN. There is a circlip on the end of that shaft (that's the shift fork shaft) that holds the gear on (it's visible in that picture. There is a washer on BOTH sides of the gear as well. That circlip is known to jump off, allowing the gear to walk outward and rub on the back of the clutch basket. Sometimes the gear can get destroyed by doing so.

The washer swap that your PO referred to is a common part of the 2nd gear fix. It should make 2nd gear engage more fully.

[CA]

This is great information. I will remove the clutch basket ASAP and report on what I find. Maybe another oscar movie will come about.

My clutch was super stiff. Anything I can/should do in there to alleviate this, while I am in there?. It was painful.

Thanks so much guys.

[CatatonicBug]

My clutch was super stiff. Anything I can/should do in there to alleviate this, while I am in there?. It was painful.

Get one of those hand-grip exercisers. If the PO installed HD clutch springs, it WILL be hard to pull in the clutch.

[CA]

tranny noise

ok so I really believe we have found it. THe PO did the 2nd gear fix, and didn't do something correctly. We flipped the bike and played with the tranny. THe 2 nd is rattling against the dog teeth because there is play in it. So most of the time when the tranny is rotating it is clanking against it making the "bolt in the dryer sound". I could acutally move the 2nd grear one way and it would would smooth and then move it the other way and it would fully engage. THerefore at normal space it just rattled against it. THere actually seems to be a lot of play in 3 or so of the gears. THe video I will post in a minute will show it exactly. Just takes a few minutes to load from my phone.

Anyways, I don't really know how to fix this. So I need the tranny gurus to tell me. Do I need to simply replace the washer to seperate something??

I probably need to check the gear and teeth to make sure they are ok.

THanks for the help.

[DGXSER]

2nd gear should be solidly mounted and have no play or movement on the shaft. 5th, 4th, and third gears slide side to side, but none of them should have any wobble.

I suggest you pull the countershaft out and inspect the gears, the shaft, and all.

[petejw]

im with dgxser, pull the gears and see
how they assembled it.

[CatatonicBug]

If ANY of the gears have ANY wobble at all, you're going to need to replace some parts. Here's one that I worked on, and the shaft was destroyed by the wobbling gear. Had to replace the shaft and a few of the gears.

[SFerinTEXAS]

Might seem like a crazy question but is the starter button intact? Last year my button came out and I resorted to sticking a key in the hole to start. Not thinking much about it a few days later became convinced a bearing was going out in the trans. Turned out the starter was staying engaged while it was running.

[CA]

Here

here is the video showing what it is doing, excuse my lack of these transmissions, it is my first time getting into them.

http://www.youtube.com/watch?v=I66tidueLxw

That is why I was wandering how the 2nd gear holds still, because even when I take it apart, I have no idea what i am doing. Guess I will be reading the tutorial like crazy!

And that starter buttion is fine, I know what that sounds like becasue I have had it happen to me before!

Thanks

Oh and keep in mind that bike was probably ridden at most 50 miles on it like this prob at least 3 miles. I do not think the PO got it running after the 2nd gear fix. And hence did not know about the God aweful noise.

[CA]

Also from the video you can kind of tell that there is not any wobble, just slidage. The the proof is in the pudding...