metal bits in the oil

[Steve TLS]

The spring looks like a spring out of an oil seal to me

[Sam]

Steve got it, that spring is off the back of an oil seal, probably the clutch pushrod one where you found it

I would hazzard a guess that at some point the chain has snapped and damaged the area around the clutch pushrod seal and that's where the metal filings have originated from

[133bhp]

the spring look slike it might be part of the seal. Often they are there to keep tension on surface. Can just break with age.

[TomM]

Thanks guys ill have a look at the push rod seal, i had no idea they had springs in them.

Sam it was in a crash and fixed up into a track bike before i bought it, perhaps that area was damaged in the crash or the chain snapped in the crash?

Whats the consensus on the fork things in the gearbox (whoops i called them dogs in the previous post) is that semicircular ware normal?

the gears also seem a fraction loose on their shaft. you can wiggle them 1mm or so either way. is this normal?

[133bhp]

the forks should'nt be scored, (or bent, nor tips be worn) its early warning of being pushed over by the gears, specifaically the prtruding dogs (correspondng grooves) that wear and are tryig to move sideways under load. So the real issue is the gears themselves. Pull apart or at least examine carefully. Sam will have pics of what should and should'nt look like or search.

There is some play on shafts but eyeball or measure the thrust washers, compare and should see if worn. unlikey, as are gears themseleves unless oil starved, and that be obvious,

Replace forks or anything suspect, I skimped on a borderline gear long time agao, trust me, its a pain pulling apart again after few hundred miles.

[TomM]

Thanks Heaps. ill pull it all appart (was hoping to avoid that ) but no way i want to do this again.

2 of the forks look almost perfect. its just the one thats a bit scoured and its tips are a little worn.

the gears look good as far as i can see but you cant really see much without pulling it all appart.

its fun but bloody time consuming.

on a seperate note has anyone made getto tools for pulling the rotor and the clutch holder off? the suzuki tools are $150 and $400

[TomM]

Well i got further, i split all the cases and still cant find where the metal bits have come from. i also pulled the gears apart but they looked fine to me. however this is the first engine ive looked inside so i thought ide take it to a local bike mechanic to look at.

he thought the dogs and the corrosponding bits on the inside of the cogs on 2 gears (2nd and 3rd i think) were slightly worn and i could see what he was talking about when he pointed it out. he also said that i should replace the shift drum while we were in there. so 2 gears, 2 forks, and a shift drum.

i have left it with him to asses further and get back to me with a quote to fix it and put the cases back together.

he will have a further look around to see if he can see where the metal has come from but he's not 2 worried about it. he said that sometimes happens and its probably just rough bits of the cases that have dislodged themselves.

also i found one of the bolts that held the crank cases together was covered in slime. the rest had a nice fresh oil coating but this one looked like it had been dipped in mud.

any explanations for that? is it something i should investigate?

[Sam]

Originally Posted by TomM

also i found one of the bolts that held the crank cases together was covered in slime. the rest had a nice fresh oil coating but this one looked like it had been dipped in mud.

Usual reason is if the bolt hole has a path to the water jacket or something. Check the other end of the hole and see where it goes.

I wouldn't be worried about it anyway

[TomM]

Thanks Sam sort of thought it was nothing.

+ the fiche parts list arrived last week

[TomM]

ok Mehanic go back to me. He wants to replace a fork, 2 gears the drum selector.

He has quoted;
$325 Gaskets
$58 seals
$96 gear1
$130 gear2
$90 fork
$195 drum
$16 Cips
TOTAL = $910 in parts + 6 hours of labour $585 = $1,495

I wasnt expecting that much!!!

I think i will do it myself but the things that im worried about are
1. we still dont know where the metal bits came from
2. will these gears, forks and drum need replacing every 12,000km?
surley not! but why now? i dont even clutchless shift on the track just normal clutch and shift. is there something else wrong causing the excessive gear ware? perhaps the previous owner was a clutz with the shift lever?
3. the second fork has some ware as well (see pic below) so if thats one is OK then surely the first one should be right as well? that or im going to have to go through the whole thing again when the second one gets worse? it seems it should be both forks and the gears that are pushing them out or nither of them. no?

i might get it back then take close up pics of the gears and see what you guys think. they really didnt look that bad. just the tinyist bit of roughness on the edges of the dogs and corrosponding slot in the gear.

i guess im not sure of my next step and i dont want to have to spend $1,000-$1,500 again. the work i like, its just the cost

pic of the forks (note the tiny crescent shape ware on the first fork (background) and the larger ware in the second (foreground)


pic of the back of the forks