H2C Gearbox

[Wolfie]

are you meaning like this?





Don't fret Max, FWIW you're not alone..

[simonh]

fcuking hell

[Wolfie]

I don't know the original cause but I'm about 8 weeks down the line having built the thing five times now and it still went 'Bang- clunka clunka clunka yesterday, when I loaded the gears.

Every time I build her up, I go through all the gears and make sure everything engages smoothly, everything looks cool and this last time I felt particularly happy about the feel, but - bang- clank clank clank..

We now have some new cases and It's looking like they might be used after all.

There is a small movement in this current gear shaft that makes the outer edge of the clutch wobble by maybe 0.1mm - barely noticeable at that distance from the rotational centre, I can't think something that small being the cause of the destruction of gears.

[scouse]

so wolfie if i get this strait, the clutch shaft spins off center under load ,,sending the oposite gear hard up to the bushing then in turn the circlip bering ect. but why does it kick the bollocks out of the side case?
i to have had it apart about six times now .but i put a 500 gear clusters and shafts and the ally welding held. last week took out 500 gears and put the 750 gears back rode 90 mils bang clatter.felt like blunt wood rasp on metal, 1st was seizing but not all at once ,.
the sick part is that the 500 gears were sweet as,but i know you cant ride a2 c like a1 a.

if you fit a h1 gearbox in a h2 it is advisable to replace the h1 second gear with the h2 second gear, especially if you ride hard.

if you have refitted your h2 gearbox that went bang, like Graham then there might be a problem with the shaft being bent

only way to measure it is with a dial gauge with the shaft between centres or on v blocks

FWIW, the engine Graham is working on has a crack on the top of the engine were a something has tried to exit the cases, suggesting what ever happened was a pretty large blow up.
this was before the bike was in Graham's hands

BTW Max did you follow Moto's transmission Manual when you rebuilt your gearbox?

http://kawasakitriplesworldwide.com/php ... 15&t=23872

Gary T

[Wolfie]

Measure those shafts Max.

Just done these two, had 0.02mm at third gear position on the input shaft and 0.08mm on the layshaft at third gear position.

I wouldn't have thought either was enough to cause this sort of devastation.

Luckily this time there are no teeth lost, the selector drum bore the brunt and broke at the outer edge where the locating plate engages.

[Wolfie]

Putting the 750, second gears onto the 500 shafts sounds like a safe bet...

I've checked all the shafts and got a set that have no measurable runout for the next build, but I noticed that the crack in the case has moved this time..

[Wolfie]

Hmmm, not sure about that one Max, I tend towards not.

Using the cases as a sliding stop, I think there will be too much friction there and the shims would both heat and wear the cases.

Better to try and cure the sideways force on the gears.

Or far easier would be the 750 second gears on H1 shafts, ten minute job.

[sweet angel]

Happy Birthday Max, have you celebrated with a ganja cake

[malc87]

happy birthday Max

[Wolfie]

Happy Birthday Max

I put this H2 back together yesterday, rode it this morning but only fairly easily, I know that I must ride it harder to break it, I'm just loathe to do it.

However, I must.. it has been sold, and I can't have it do this to the new owner.

I hate breaking things.