Hayabusa Gearbox - the fixed model

[Madmax]

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.

Hi Bone,
she was lurching at the hiugher rev rate - around 6 to 7,000 rpm and up she would suddenly lurch out of gear and back into gear. The first time she did it I lost traction on the back tyre and left a nice black squiggle on the tar - scared the shit out of me. Then it did it again. I had an '84 FJ1100 that did the same thing but was covered by warranty, so I knew what was happening.
Goingeasily through the gear and nothing would happen, so it was only when I was getting towards maximum horsepower through the gearbox that had her doing it.

I took the clusters down to my local bike shop and had them tell me what to replace - the pictured cogs and selector fork. As you can see from the poicture, the selector fork was munted well and truly.
Pete has suggested also putting heavier quality guide rods for the selector forks, if I have to do this again I'll be using his suggestion.


Max

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

Mike, do yourself a favour mate, get rid of the Haines and get a Shop Manual if you're going to do this job. Just can't speak highly enough about the manual, and I'm nusing a Haines for my old GPZ550 rebuild - they just don't compare.
I'm going to suggest that you get a hold of 2 Warren and Brown torque wrenches. That way you'll avoid the heartache of broken or threaded bolts.
The first is in the 10 to 220in/pounds range. The easiest bolts to f*** completely are the little ones that the manual tells you to tighten to 7ftlbs. There are so many of the little turds and you only have to strip a thread or brake 1! to bugger the job and turen into a nightmare of heli-coils/ easi-outs etc.
The 2nd is in the rnage of 10 to 80 ftlbs, that's the rest of the bolts in the motor. Niether of these things cost peanuts. Remember the old saying "Pay peanuts get monkeys!"
Don't go to Repco or any of the other major motor repair tools shops. I they'll charge you over $300 for each of these suckers. However I got them for over $100 off each from Fisher Discounts here in Canberra, ring them and ask for a decent price.
Remember 1 busted or screwed thread can really cause you drama!


Good luck with the job.



Max