3rd gear - Page 3

mattbren · 06-01-2010, 10:34 PM

3rd gear finally fixed after 9 months, thanks to macmac for all his advice. Lost hte memory card from my camera, when I find it I will post photos. A big learning curve but a good experiance, absolutley fantastic to ride it again.

jandreu · 06-02-2010, 01:48 AM

mattbren, really glad you got it fixed. I'm also really glad you updated this thread as I had not seen this and this is one hell of an education.

How about some details on the repair. What did it turn out to be?

mattbren · 06-02-2010, 05:02 PM

3rd gear output gear and a chipped skirt on the rear piston. Would recomend to get 3 manuals to do the job as the 1500 manual is not tje same as the 1500 transmission, the 1600 was spot on in decription and how to test it properly, would of saved me splitting the case several times. But doing all that gives me a new appriceation for the bike and the workings. will post pictures when I find the memory card for the camera. At first it made it real hard not having them, but reading 3 manuals really helped.

macmac · 06-02-2010, 05:33 PM

WOW..... And what was the 3rd manual? one for 1500, one for 1600 AND????

jandreu · 06-02-2010, 07:57 PM

I think he means a regular 1500, a 1500 transmission and a 1600 manual. Just my guess. ;)l

So did the chipped skirt just show up during disassemble or was it also giving some sort of indication of trouble before you broke the engine down?

mattbren · 06-02-2010, 08:38 PM

First was the clymers for the 1500 98-2004, 95-98 1500 last 1600, alot better details on the trans, the clymers was wrong, it had the shift forks ion the wrong position and no details on testing like the 1600. Should have checked the old gear with the new one as the were different to, 4mm smaller holes for the feed dogs to go into, found this out after the bike was in and running, stuck in 3rd gear, take out and split, scratches on feed dog, carefuly file down gear holes, seemed to work, fit engine, same thing, take out and split, took a die grinder to the hole top and bottoms, found the 1600 manual, tested it properly and worked really smooth.
The chipped skirt was a tooth mark with a fine hairline fracture found at cleaning the part.

jandreu · 06-03-2010, 01:14 AM

Thanks for the info. I know who to ask if I need to open my cases up.

mattbren · 06-03-2010, 06:54 AM

no problem

06-01-2010, 10:34 PM	#31
mattbren Jr. Member Join Date: Apr 2009 Location: Adelaide Posts: 35	3rd gear 3rd gear finally fixed after 9 months, thanks to macmac for all his advice. Lost hte memory card from my camera, when I find it I will post photos. A big learning curve but a good experiance, absolutley fantastic to ride it again. Login or Register to Remove Ads
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06-02-2010, 01:48 AM	#32
jandreu Sr. Member Join Date: Jan 2010 Location: Makawao, Hawaii Posts: 1,409	3rd gear mattbren, really glad you got it fixed. I'm also really glad you updated this thread as I had not seen this and this is one hell of an education. How about some details on the repair. What did it turn out to be? __________________ James Andreu '07 1600 Red/Silver VBA Member #1356 jandreu@hawaiiantel.net
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06-02-2010, 05:02 PM	#33
mattbren Jr. Member Join Date: Apr 2009 Location: Adelaide Posts: 35	3rd gear 3rd gear output gear and a chipped skirt on the rear piston. Would recomend to get 3 manuals to do the job as the 1500 manual is not tje same as the 1500 transmission, the 1600 was spot on in decription and how to test it properly, would of saved me splitting the case several times. But doing all that gives me a new appriceation for the bike and the workings. will post pictures when I find the memory card for the camera. At first it made it real hard not having them, but reading 3 manuals really helped.
	0

06-02-2010, 05:33 PM	#34
macmac Sr. Contributor Join Date: Apr 2008 Location: Tamworth New Hampster 06 1600 Posts: 12,484	3rd gear WOW..... And what was the 3rd manual? one for 1500, one for 1600 AND???? __________________ 06 1600 Nomad Just call me Mac molon labe come and get it
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06-02-2010, 07:57 PM	#35
jandreu Sr. Member Join Date: Jan 2010 Location: Makawao, Hawaii Posts: 1,409	3rd gear I think he means a regular 1500, a 1500 transmission and a 1600 manual. Just my guess. ;)l So did the chipped skirt just show up during disassemble or was it also giving some sort of indication of trouble before you broke the engine down? __________________ James Andreu '07 1600 Red/Silver VBA Member #1356 jandreu@hawaiiantel.net Login or Register to Remove Ads
	0

06-02-2010, 08:38 PM	#36
mattbren Jr. Member Join Date: Apr 2009 Location: Adelaide Posts: 35	3rd gear First was the clymers for the 1500 98-2004, 95-98 1500 last 1600, alot better details on the trans, the clymers was wrong, it had the shift forks ion the wrong position and no details on testing like the 1600. Should have checked the old gear with the new one as the were different to, 4mm smaller holes for the feed dogs to go into, found this out after the bike was in and running, stuck in 3rd gear, take out and split, scratches on feed dog, carefuly file down gear holes, seemed to work, fit engine, same thing, take out and split, took a die grinder to the hole top and bottoms, found the 1600 manual, tested it properly and worked really smooth. The chipped skirt was a tooth mark with a fine hairline fracture found at cleaning the part.
	0

06-03-2010, 01:14 AM	#37
jandreu Sr. Member Join Date: Jan 2010 Location: Makawao, Hawaii Posts: 1,409	3rd gear Thanks for the info. I know who to ask if I need to open my cases up. __________________ James Andreu '07 1600 Red/Silver VBA Member #1356 jandreu@hawaiiantel.net
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06-03-2010, 06:54 AM	#38
mattbren Jr. Member Join Date: Apr 2009 Location: Adelaide Posts: 35	3rd gear no problem
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