metal bits in the oil

[TomM]

you can see the drum in thos pics to. it looks ok to me?

[Sam]

Those forks look ok to me, it's usually the smaller fork that wears the most.

See if you can get some good pics of the dogs on the gears in question.

It's very rare for a drum to need replacing, check the grooves for steps especially near the tight corners

$100 an hour for labour !! I need to charge much more

[133bhp]

I'd replace the pair of forks, with any sign of wear/stress/not square to each other. THe drum is highly unlilkely, but post up the gears. I reuse gaskets bar head/barrel?

[The Ring-In]

Tom the drum and the forks are only there to put the gears in place. once in gear they have no further use until you need to change again. its the integrity of the gear dogs which is critical to the operation of the box. so as long as the forks and the drum carries the gear to an engaged position. the gear itself will draw itself into a fully engaged position and maintain it.
if the gear dogs are worn then the forks and drum become defacto dogs trying to hold the gears in place.
So IMO a bit of wear is no great drama .
gear engagement and dog condition is critical.
I wouldn't replace the ones you have but I would be very thorough about checking the way the dogs engage and the shape of them and the slots they engage too.
as for the service intervals on the box that is all relative to the pattern of use . hurried and haphazard shifts can be incomplete and cause the dogs to jump and the forks to wear and bend. positve shifting and a properly functioning box will last a long time.
poor shifting habits and aggresive use of the throttle will wear it in no time.
quality of oil will affect wear in the bearings and shafts and the root tip contact areas on the gear tooth itself.
expect to see some sheen in the oil . if in doubt in future it is possible to have a samle analysed and they can fairly acurately determine which part of the engine it came from by its metalurgy.

there are companies set up to recut the dogs and recut the engaging slots. someone posted about this recently.

[TomM]

ok. Thanks guys ill get the engine back off him and post up some good pics. The more i think about it the more i think there isnt much wrong with it. the ware he was showing me on the gears was very minor. but ill post it up and get the consensuses.

[TomM]

Ok got the engine back and took photos of every gear and dog.

the worst one by far is first. second had a litle damage i guess but the rest are pretty much perfect.

First Gear Pics




Second Gear Pics







Does second need replacing?

[TomM]

Better pics of the Forks and drum






really i cant see much wrong with the drum. the forks i havent checked yet for straightness or thickness but assuming they are straight and within spec how does the ware look?

the small (5/6 gear) ones tips look a little rounded but the gears and dogs it pushes look perfect. The tips of the 2 big ones seem in good nick but the 2nd gear and dogs is the worst gear

[TomM]

does this look normal


i thing its just rough machining but i thought ide ask.

[TomM]

There is a little mark on one one of the cylinders that looks like it could be from one of the valves just touching the cylinder head. This pics are a little fuzzy and i have to do a lot more investigation on this i think but i thought i would see what your initial thoughts were.
Cylinder head


Corresponding Valve (top left valve in pic)

[TomM]

and lastly (thanks so much for making it this far) i think i may have damaged the surface coat on this cam during transport it feels rough when i run my finger nail over it.

Will i need a new cam shaft or is this ok or fixable. i have a feeling it will need replacing