4th Gear problem

[zippytlsr]

WEll, I was at the track moving along pretty good (t-hill) leaving turn 15 in 3rd, dont know what my rpm's were, but the bike was screeming so i would guess about 9 or 10K and shifted into 4th. I used the clutch, or so i thought. Well when 4th ingaged, the bike made awefull clunky noises. I shifted into 5th and noises gone. Back into 4th and clunky's were back. Shift into 3rd and smoooooth rolling. 2nd is smoothe,1st is smooth.

So my guess is i broke a dog off, or broke a tooth or two off the gear/s. Now that this is my second motor, the first is still sitting on my garage floor-99 S Motor, I am running an 02 R motor at the moment.

So my first question.... of many.. Do i need the special tool to SPLIT the engine cases? I plan on doing this myself.

Do i need a special tool to get the clutch basket off?

Should i remove the Generator or can i leave it in/on the shaft?

What Nuts/Bolt are REVERSE threaded that i need to be carefull about?

Do i need to hone the CYLINDER bore and get new Rings to reseat with?

Is there a Gasket List somewhere i need for this?

Will the Parts from my 99 bottom end Fit my 02 bottom end?

Is the 02 motor better than the 99? or are they the same less oil heatexchanger.

I was told when i purchased the motor that it had less than 7 thousand miles on it so i am figureing that i wont need bearings.. i hope.

IF YOU had the motor apart would you get the crank and pistons balanced while you had it apart? I am thinking i should.


Please let me know any tips or tricks you have on this. I think i should be able to do this with my manuals/digital cam and laptop with TLZONE running. I think that the hardest part will be getting the broken parts replaced.

I really want to get it fixed and ride again. My lap times were coming down!!

Thanks in advance guys and gals!

[Gigas]

Welcome to the club, zippy!!!

Sorry for not having any replies to your questions but I will also need any help given here...
Tomorrow I will start stripping down my bike to find out what's the damage on my motor...
I will give all the info I gather in this thread...

[BikePilot]

I put what I know in green - others will be of much more help I'm sure

Originally Posted by zippytlsr

WEll, I was at the track moving along pretty good (t-hill) leaving turn 15 in 3rd, dont know what my rpm's were, but the bike was screeming so i would guess about 9 or 10K and shifted into 4th. I used the clutch, or so i thought. Well when 4th ingaged, the bike made awefull clunky noises. I shifted into 5th and noises gone. Back into 4th and clunky's were back. Shift into 3rd and smoooooth rolling. 2nd is smoothe,1st is smooth.

So my guess is i broke a dog off, or broke a tooth or two off the gear/s. Now that this is my second motor, the first is still sitting on my garage floor-99 S Motor, I am running an 02 R motor at the moment.

So my first question.... of many.. Do i need the special tool to SPLIT the engine cases? I plan on doing this myself.

Do i need a special tool to get the clutch basket off?nope, just an impact gun

Should i remove the Generator or can i leave it in/on the shaft?
I think you'll have to remove it to get the cases apart you'll need a flywheel puller/big bolt I think

What Nuts/Bolt are REVERSE threaded that i need to be carefull about?
I don't know

Do i need to hone the CYLINDER bore and get new Rings to reseat with?
No! Don't hone plated cylinders (imho).
Is there a Gasket List somewhere i need for this?

Will the Parts from my 99 bottom end Fit my 02 bottom end?
I'm pretty sure they will

Is the 02 motor better than the 99? or are they the same less oil heatexchanger.
The botom ends I think are the same, the R model has different heads, cams and pistons

I was told when i purchased the motor that it had less than 7 thousand miles on it so i am figureing that i wont need bearings.. i hope.
dunno, if I did all the work to take it apart I'd be inclined to put in new bearings and shells I think

IF YOU had the motor apart would you get the crank and pistons balanced while you had it apart? I am thinking i should.
dunno, my TLS always vibrated a lot so I probably would, but if its not objectionable in that regard I don't think I would

Please let me know any tips or tricks you have on this. I think i should be able to do this with my manuals/digital cam and laptop with TLZONE running. I think that the hardest part will be getting the broken parts replaced.


I really want to get it fixed and ride again. My lap times were coming down!!

Thanks in advance guys and gals!

[zippytlsr]

Gigas.... how did you do your tranny in?

Bike pilot.. thanks for hte input!! I think i will see what a basket case i have gotten myself into before doing a complete rebuild.

SAM... where are you? I figured you would have ALL the answeres

TLDV8..... Thought you would have chimed in by now as well...

TLRdoug..... any good words of wisdom?

[Gigas]

[quote=zippytlsr;1206790]Gigas.... how did you do your tranny in? [quote]

No tranny problems here... A couple weeks ago my motor's crack went south.
Gathering info about opening the cases is what interests me

[zippytlsr]

oh ok, well hopfully lots of people feel pity on us and chime in soon.
I hope to take my motor apart next week and see what's going on. I gotta make a ton of room in my garage to even get the motor out of the bike!! then get a couple of freinds over to help with the rest of it. I'll keep ya posted.

[133bhp]

133bhp = red

Hope this will help given not the names you requested! ...

Do i need a special tool to get the clutch basket off?nope, just an impact gun

if you dont have access to a special tools, my advice is leavr the drive chain on, and lock/brake the rear wheel, you can then undo the major items. (espcailly the clutch basket) insitu. When the engines on the bench, you can strip down without further ado.

Should i remove the Generator or can i leave it in/on the shaft?
I think you'll have to remove it to get the cases apart you'll need a flywheel puller/big bolt I think

you dont need to if not removing the main bearings (on the left side) hence dont need the gen bolt either.

What Nuts/Bolt are REVERSE threaded that i need to be carefull about?
I don't know

the cam drive sprocket

Do i need to hone the CYLINDER bore and get new Rings to reseat with?
No! Don't hone plated cylinders (imho).

No, but pently of wide open/closed throttle will help seat them.

Is there a Gasket List somewhere i need for this?

Yes, search ron ayers - but you dont need a full set, cheaper to but whats needed. (UK prices)

Will the Parts from my 99 bottom end Fit my 02 bottom end?
I'm pretty sure they will - ditto

Is the 02 motor better than the 99? or are they the same less oil heatexchanger.
The botom ends I think are the same, the R model has different heads, cams and pistons

I was told when i purchased the motor that it had less than 7 thousand miles on it so i am figureing that i wont need bearings.. i hope.
dunno, if I did all the work to take it apart I'd be inclined to put in new bearings and shells I think

yes, and output shaft bearing and oil pump too if not perfect.

IF YOU had the motor apart would you get the crank and pistons balanced while you had it apart? I am thinking i should.
dunno, my TLS always vibrated a lot so I probably would, but if its not objectionable in that regard I don't think I would

Please let me know any tips or tricks you have on this. I think i should be able to do this with my manuals/digital cam and laptop with TLZONE running. I think that the hardest part will be getting the broken parts replaced.

serach, I've myself wriiten on this a few times, as well as many others. adjust squish is cost free for starters though,

I really want to get it fixed and ride again. My lap times were coming down!!

[zippytlsr]

THANKS 133!! Yes i did some searching... started with spitting cases, tranny issues, then to 4th gear. My eyes started bugging outta my head so i posted up for some help.

ANY AND ALL HELP IS GREATLY APPRECIATED


I had an oil issue i believe in my first motor that siezed my Exhaust cam in motor 1, so i found another motor "in great shape with less than 7k garanteed" on it and did the transplant. I paid way too much for my 2nd motor but was under the gun for time. so i paid outrageous money for it. now that its down.. there's no way i am NOT splitting the cases and fixing it. This last track day was my last WHO RAA! for the season.... so i have time and No Money now. ... so she's getting fixed. I am really nervous about splitting the cases, just cuz it's such a jig saw puzzle inside.. or so it seems.

I have rebuilt an old 4cylinder motor a couple of times... not to hard.. but they have big parts and big bolts. I feel confident with everyones help I should be able to get this done.

[Steve TLS]

An M20 X 1.5mm bolt is needed to get the flywheel off the crankshaft.

[zippytlsr]

Thanks STEVE...

I dunno what happend to search last night... but it's workign better this morning?? I did another search and found what SAM had posted before,
When ever I rebuild a TL engine, I always replace the oil pump, big end shells and gearbox output shaft bearing. This ensures you have a solid bottom end that will last a long time and be a good basis for any future mods.

Bearings are cheap if you get them from a stockist but some are odd sizes like the 97 Gearbox output bearing and the cam chain drive shaft bearings.

All seals etc can be done without splitting the cases so not as important.

Check the gearbox carefully for warn dogs and chipped corners, also check the selector forks for wear and gouging etc.

A quick selection of parts I've bought

Oil Pump 16400-02FB0 £70.25
Head Gasket 11141-02F01 £17.47
Base Gasket (Front) 11241-02F01 £8.67
Base Gasket (Rear) 11242-02F01 £8.67
Clutch Cover gasket 11482-02F10 £9.99
Seal Clutch Pushrod 09285-06015 £8.72
Gearbox Circlips 09380-27001 £0.66
Seal Behind Front Sprocket 09283-38020 £11.84
Outer Gearbox Output Bearing (28x68x20) 09262-28040 £44.22
Inner Gearbox Output Bearing (20x52x15) 09262-20082 £16.13
Centre Shaft RH Bearing (25x62x17) 09262-25073 £12.25
Centre Shaft LH Bearing (20x47x14) 09262-20139 £16.29
Big End Shells (Black) 12164-02F11-0B0 £8.57
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So the search will continue... thanks Sam