Tranny rebuild... and more

[mbarr10]

All right then I have new News? Started new thread from 1700 big bore.

Input and out put shafts have a 2 week wait, into the country then a week or so for shipping to Minneapolis? Then assembly. All new tranny install. gears , dogs, and shafts.
Now the goofy part, Head bearings shot also. WTF Never had such issues with a Kawasaki. 2016 with 11,000 miles. Disillusionment is setting in.
Maybe I can ride again in MAY. Warrantee work but really Mama Kaw??

Dealer, Great. Call backs, Keeping me up to date with out calling. Very satisfied. Somebody is going to sell me my next bike here. Plus they are an Indian dealer, HMM. Can you say Scout??

Looking into if Raycnray can under cut second gear for me during the process of the wait.

[RACNRAY]

Some gears from a 1700 in my shop gettin undercut...

[ballbreaker]

Makes one wonder. Only had Kawasaki since 1994 except for a 2010 Roadking. After totally it back to nomads and now Vaquero with little or no problems ever. Good luck with whatever you do.

[redjay]

Originally Posted by mbarr10

All right then I have new News? Started new thread from 1700 big bore.

Input and out put shafts have a 2 week wait, into the country then a week or so for shipping to Minneapolis? Then assembly. All new tranny install. gears , dogs, and shafts.
Now the goofy part, Head bearings shot also. WTF Never had such issues with a Kawasaki. 2016 with 11,000 miles. Disillusionment is setting in.
Maybe I can ride again in MAY. Warrantee work but really Mama Kaw??

Dealer, Great. Call backs, Keeping me up to date with out calling. Very satisfied. Somebody is going to sell me my next bike here. Plus they are an Indian dealer, HMM. Can you say Scout??

Looking into if Raycnray can under cut second gear for me during the process of the wait.

Head bearings shot at 11,000 miles ? Were they overtightened sometime or never been touched since new ? 11,000 miles is way too soon for head bearings to need replacing. Is that what the dealer told you ?

[mbarr10]

Originally Posted by redjay

Head bearings shot at 11,000 miles ? Were they overtightened sometime or never been touched since new ? 11,000 miles is way too soon for head bearings to need replacing. Is that what the dealer told you ?

They took Pics Sent them to Mama Kaw and they said they would replace them. FREE. I had tightened them 2 times, they did not stay tight. Never done this before so I may have goofed it up. Locking ring in place after each try and bounced on the front then re checking. Swung side to side tight, Loosened , re tested, swung good. Each time. So it seemed pretty straight forward after reading and watching many Vids. Delboys Garage, saved comments I read here ect, ect. Reputable sources.

My only thought could be I over tightened them, because I used a socket and not the Spanner wrench. However because of the angle difference I realized the torque would not be the same. So I went by tightness of the side to side steering and not the Spec torque. I did work my way slowly up to tight then backed off some. !/8th turns at a time.

[mbarr10]

I just got off the phone with Ray and the place where the dogs slide into the gear does not allow the gear to fully engage with the dogs. He cuts away material on the gear to allow a better deeper engagement of the dogs into the gear. As I understand it.
PM him and he can really explain it. I am not a mechanic.

Now if the dealer cooperates I will send the gear and dogs to Ray to make a better lasting engagement.

By the way he also mentioned that his head bearings notched at 18,000 mile for him and the all balls replacement lasted the 80,000 plus miles after the replacement before he sold his Vaquero with them still in working order.

For me good stuff to know, YMMV

[smokier]

MBarr, brother I am feeling for you, having to go through all of this! Did you say that the dealership where your VAQ is at is also an Indian dealer? AND, Mama Kaw is paying for all of this work under Warranty? This dealer is working well with you and keeping you updated and they are trying? Am I on track so far?

And, a few months back didn't you post that your Favorite Kawi dealer had closed their doors?
It seems to me that fate may be guiding you to a new ride. You put too many miles on and get out there too much to not have a scoot until MAY...


Sorry, probably a post from Captain Obvious.

Let me know how I can help.


Ride safe,
Smokier

[RACNRAY]

5th and 6th gears undercut and input shaft assembled. One thing I found with this shaft is one of the thrust washer and circlip holding 2 of the gears in place were showing excess side load and were deformed, eventually the circlip would fail, either by breakage or being pushed outa it's groove.

Last time this engine was opened up due to a gear actually breaking and metal particles got in the oil pump which scored the machined surface in the case, the cases were replaced. Cases dont come with bearings and/or races installed, they have to be pressed in. Setting up that shaft with those 2 gears in place proved either the race or the bearing had not been pressed in all the way. I heated up the case and knocked on both hard, but neither moved even .001", so they are stuck where they are.

In order to gain clearance so there is no pressure on that clip, I machined the thrust surface on one of those gears and gained the required clearance.

I gots all my engine parts from Kawi so I can get started on replacing and cutting the gears on the output shaft.

MORE TO COME......

[mbarr10]

[ATTACH]IMG_20200321_134347705_HDR.jpg[/ATTACH]

Visited my bike today at the shop. I almost cried. 2-3 more weeks wait. I picked up the gear to send off to Ray for undercutting. Dealer said this is the second 1700 they have gotten in for 2nd gear slippage. Still waiting on the gear shafts from Japan. Supposedly they are on the way? 2 more weeks to maybe arrive at the dealer from the dock in California. If they don't shut down

[smokier]

WOW, that is hard to look at. Best hopes and prayers that everything comes together in timely fashion.


Be safe,
Smokier

[mbarr10]

Appreciate it Brother

[ldhthept]

On a lighter note, in the first picture, I thought that was your helmet sitting on your seat. Angry Bird? Ninja Turtle?

[mbarr10]

Hah, It does look like an angry bird.
I was in a hurry not to take anyones time up at the dealer so I just did a few shots and left. Put my tabs on, grabbed 2nd gear and the associated cog to send off for undercutting.

[RACNRAY]

mbarr10...got your gears in today but am a bit behind as I ran into problems yesterday with the head on this KZ1000 I am building, and my goal was to get the head on today and start my multi torking process. I will do 2 re-torks today, let it sit overnite and final tork tomorrow.

Your gears are my next victim as my orthodontist would say when he came into the exam room!!!

[redjay]

What is the purpose of undercutting the gears, deeper engagement or less of a dog on the gear to engage with the next gear ?