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07-09-2010, 10:16am

Lookimg good mate. The knee must be coming along well if you can stand and crouch while doing the motor.

**Throwdown!** · 07-09-2010, 04:06pm

That's mechanical porn.

I couldn't tell the difference between any of the shots, but seeing naked mechanics does it for me.

That's a fairly early busa with the black frame, so it must get used properly - my 2000, 150,000km busa is nowhere near having gearbox problems.

**Madmax** · 07-09-2010, 04:25pm

(07-09-2010, 10:16am)BLACKZOOK Wrote: Lookimg good mate. The knee must be coming along well if you can stand and crouch while doing the motor.

Hey Bruce, the constant getting up and down working on her getting the motor out and then back in was hectic physio let me tell you.

The way for me to get onto the floor is a controlled fall, getting up using the new prothesthetic knee is such good exercise............the first 100 times. Pi_freak

But the very best physio is riding the damned thing. Nothing better! Smitten

Did the Loaf pick that radiator up yet?

**pan** · 07-09-2010, 04:25pm

Don't think it's a rider issue Throwdown.
It just seems to surface on the 04 models onwards...

**Throwdown!** · 07-09-2010, 04:31pm

Really! That's a downer. I thought a later busa bike would be great second bike at some point, as they'd be the best examples. What changes have caused them to have gear problems?

**pan** · 07-09-2010, 04:37pm

The only rational guess I've heard was by Volvi some time ago. He said that maybe the equipment that puts together gearboxes was showing signs of wear and tear from 2004 onwards, or maybe they had been outsourced...?

**gggsxr11** · 07-09-2010, 05:52pm

lookout madmax there is a kawasaki spy motor in the vicinity trying to learn how hayabusa motors make so much power,it will probably be gathering then return to mother kawasaki with all the secrets.

**Madmax** · 07-09-2010, 09:19pm

(07-09-2010, 05:52pm)gggsxr11 Wrote: lookout madmax there is a kawasaki spy motor in the vicinity trying to learn how hayabusa motors make so much power,it will probably be gathering then return to mother kawasaki with all the secrets.

As long as the Kwacka whacka secrets don't run off on dear old cheesecake Suzuki mate. Don't forget that this gearbox error was the worst with the M109s, exactly the same problem. Suzuki has been having these issues for some years, it's time they owned up to their cheesecake gearboxes! Roll

10-09-2010, 08:00pm

Awsome effort. Most would not take such an overhaul on. Good work there.

**Madmax** · 10-09-2010, 09:17pm

(10-09-2010, 08:00pm)heavensdoor Wrote: Awsome effort. Most would not take such an overhaul on. Good work there.

Thanks bloke. Not my first but my first in a very long time. All it takes is patience a little ability and a great workshop manual! Lol3

16-09-2010, 10:56pm

Well done and thanks for the pics. I have just decided to basically do the same job myself on my '09 after seeing them. Was not looking forward to spending upwards of 1200 bucks to replace a $4 seal but didn't have confidence enough to attempt the job Confused

.... I will try to better 30 hours though..lol. BTW. Which manual do you have ?? I have the haynes and it seems ok.

**Greeny_SA** · 16-09-2010, 11:48pm

Keep your wits about you ,as I have recently helped Busabazz do some work on his & I Think some of the torque figures quoted in the haynes
book may be wrong . I don't think you can tighten up a 6 mm bolt to 23 n/m without ripping the head off .I have a genuine Suzuki Service manual which occasionally differs from the haynes one , trouble is ,the suzi one was $160 4 yrs ago . just use common sense .

**fasterfaster** · (This post was last modified: 17-09-2010, 05:48am by fasterfaster.)

Which seal is teardown needed for ? ? ?
Greeny usually when that happens some one has over tensioned the bolt and stretched it, if the bolt has a tensile rating number on it's head then your ok to go (usually marked 4 6 or 7)

**Bone** · 17-09-2010, 05:22am

G'Day Max,

Job well done.

Just wondering what was going on with the box that prompted
you to pull it down? And what did you change to fix it? Did you get
the teeth undercut in the process? Were any of your selector forks
bent?

I've probably missed all this on earlier threads.

Cheers Bone.

**drworm** · 17-09-2010, 06:44am

(17-09-2010, 04:44am)fasterfaster Wrote: Which seal is teardown needed for ? ? ?
Greeny usually when that happens some one has over tensioned the bolt and stretched it, if the bolt has a tensile rating number on it's head then your ok to go (usually marked 4 6 or 7)

The clutch pushrod seal would need case splitting to replace.

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