Holy mutha :( !$%^$%£^$£

[IOWNATL1000S]

Well i have now go the cases split and had a look at the gearbox,,,,,,,,,,,

BUGGER!!!!!!

1st, 2nd, 3rd, 4th, 5th, and 6th output/final drive cogs are no good

will post some pictures soon,, but could do with advice on the pictures i post as to whether you think i need to replace them all,,, i have noticed wear, chips on the edge of all cogs/dogs on the output shaft,,, the shaft itself looks good but the selector forks are all shot too,, one of them has got so hot at some point that it has turned blue and deformed at the end of the fork!!!!

not quite sure how they have all got some form of damage on them,, bad set of cogs?

anyone got a rough idea how much i am looking at for new cogs??

[IOWNATL1000S]

used for removing flywheel, M20 bolt with a 1.5 pitch at 50mm long (70 pence lol)



after the flywheel is off



cases split



gearbox stripped and problems found

[IOWNATL1000S]

well these are the close up shots of all of the gears....

selector forks first.....







now the gears....

[tillerdog]

well that one set of dogs is bad enough to where the fork was trying to hold it in gear..once engaged the gears are meant to stay together on their own,usually undercuts on the dogs ensure this,the problem surely started with an idiot stirring the gearbox...oops... you got the bike this way right ?

[IOWNATL1000S]

from when i got the bike i noticed a slight jump/stutter in third gear, but because it was momentary, and erratic i thought it was fueling,, but then on a ride out it just let go of that gear altogether.

and what do you mean by stirring the gearbox never heard that before

[tillerdog]

in the photos it looks like you have one gear thats minor wear(usable) and one fork looks ok... but it could be bent and not burnt yet,but that is an opinion from the couch and a guy would need more detail to say ok these are good those are bad,but for sure you have a $$$$$$ in bad parts

[ezzywave]

I've seen 250cc motocross bikes that almost, but not quite, look that bad. And they only use the clutch about 10% of the time...

[BikePilot]

I've not even seen an MX bike that bad and I've stripped mine after years of clutchless shifting

Really looks like someone was really ham-footed and just forced it in and out of gear. That or someone confused the gear shift for the foot peg and stood on the wrong one Or I suppose a set of dogs could have been defective and caused a chain reaction type thing, but seems sorta unlikely

Whatever the case, it will be right as rain once you get new bits in there. I seem to remember doug saying it cost him about $400 to refresh the gearbox, but I'm not sure if he had to replace everything or not. Depending on prices there it may be worth sourcing parts from the states and having a zoner forward them on to you. Check out www.ronayers.com for pricing and xe.com for exchange rate. Shipping would be a bit pricey, probably $50 or so as a very rough guess (I don't know what the gearbox bits weight - if you do as you've got the old ones there you can weight them up and use the shipping calculator on www.usps.gov ).

[tillerdog]

yeah like pilot said,you can also check-out these guys, bike bandit
http://www.bikebandit.com/partsbandit/basket.asp
for prices,if you need help with ordering or shipping i can help,cheers
gearbox parts will fit in a usps priority mail flat-rate envelope,my cost is about $13,4lb limit,anywhere in da woild,its easy with paypal

[IOWNATL1000S]

thanks guys,,, i really think that i would prefer to replace everything,, as even a slightly suspect bit might go soon, and if i get it back together with new bit and something goes and tears the new ones to bits,,,, i am back at square one,, just far angrier LOL and with less cash.

I will find out spares prices here first,, and if it costs more than the bike, then i will look at taking you up on your offer. (and thank you for that offer too )