Hayabusa Gearbox - the fixed model

[Maj]

You have had a practice now Max, it will be good this time ,
Max don't order a new shaft unless thats the deal you have with Glen as i have actually 2 output shafts here that are just gathering dust .

[Madmax]

Hey Pete, I'm seriously considering dilling a small hole through just below (actually above with the motor reassembled) the hole the locator button made, then put a small bolt in through the hole to stop the button leaving it's spot. What are your thoughts please? Will this weaken the case? I'm thinking of using some loc-tite to keep the little nut in place with the heat and vibrations in the box. Thoughts?

Thanks, I'm not sure it even needs this done as once in place I can't see the bearing cap moving at all.


Cheers.


Max

[fasterfaster]

Hey Pete, I'm seriously considering dilling a small hole through just below (actually above with the motor reassembled) the hole the locator button made, then put a small bolt in through the hole to stop the button leaving it's spot. What are your thoughts please? Will this weaken the case? I'm thinking of using some loc-tite to keep the little nut in place with the heat and vibrations in the box. Thoughts?

Thanks, I'm not sure it even needs this done as once in place I can't see the bearing cap moving at all.


Cheers.


Max

Max I'd either go with a dob of weld as Maj suggested or the reason I would use a roll pin over a bolt is you can get a roll pin down to about 1/16 in diam Just drill a 1/16 hole and tap an loctite it in. But I would use something physical to make sure that the locator cannot move away from it's position. I'd also use a new bearing as it's most likely damaged also.

[Madmax]

Thanks Pete, I'll use a 2mm roll pin plus Steel-Reinforced Epoxy Putty to hold the locating pin in place and see where we go from there. The pin will hold the putty firmly in place when it goes solid.

Thanks you guys, great suggestions.

Back to the shed!


Max

[Madmax]

It all went back together well, I did put a washer in the starter clutch, which gave me an excrusciating noise, then, after callinh the Legend and screaming "HELP" down the phone line I took the washer out and hey presto, just like a bought one!

Thanks to Pete and Leonard for their expert assistance, they are both awesome with Hayabusas!

Rode the old girl to work today and she fairly hummed to be able to select 1st gear again!!!




Max

[Madmax]

The pictures of the event tell their own story, to get the gear selector cover off so I could get the washer back where it should have been we had to remove:

both fairings, overflow reservoir, front sprocket cover, water pump, front sprocket, all the bolts holding the selector cover on and then to get at the last bolt at the bottom right of the selector cover, loosen all engine mounts, air box, and get the jack going again -then with all the above loosened using a large and very long screwdriver, lever the whole rear of the f*&^ing motor up to get a T bar onto the remaining bolt and remove it. The frame gets in the way of removing the last bolt, the way to avoid this in the future - shorten the bolt about 5 mms while it is out. When removing the gear selector cover make sure you have something to catch the litre or so of oil that spews out!+

All this to get this washer back to where it belongs on the gear selector shaft!


The little bolt hidden by the side stand mount - part of the frame.


The bolt - too long to get out without lifting the whole motor.


The shift shaft as it came out


The shift shaft as it should have looked and when it went back in.


The black beast back together.

[pan]

This is the best thread ever!

[Madmax]

This is the best thread ever!

When Leonard told me what I had to do to get that washer where it should have been I was shocked and less than amused, now I have learned another lesson. That lesson being that, the manual shows and tells you to put a washer between the starter clutch and the case, and a wave washer on the outside between the starter clutch and the starter clutch cover. That is for pre-2003 Hayabusas not subsequent models - NO FARKING WASHER!!! just the wave washer - otherwise it makes a shrieking noise when you start her up!

Thanks Leonard - you are the Guru of the engine without a doubt!


Cheers Pantheman!

[Fineline22]

[ducsguts]

Well done, thanks for sharing your experiance and the pics.

[Madmax]

Thanks guys, you are both more than welcome.

All I have to do next is the top end when it starts to give trouble. I think that may be a little (LOTS) more complex.


Cheers



max

[Heidi1]

Good on you mate. And NICE PHOTO!

[Shifu]

Sincere congratulatons Madmax on tackling this work by yourself. There is no bigger satisfaction than working on your bike and learning in the process. Even if not all is perfect the first time the lessons learned are never forgotten. And it is such a privilege to be able to relay and the best advice available from people like Peter, Leonard or Maj. And many others as well willing to help the fellow club member. That for me is the essence and the reason we are all banded together here. Fantastic work mate

Going through the pics I could not help not to notice the powder measure and the reloading press. You didn't try to top the horsepower up with some, did ya?

[Madmax]

Sincere congratulatons Madmax on tackling this work by yourself. There is no bigger satisfaction than working on your bike and learning in the process. Even if not all is perfect the first time the lessons learned are never forgotten. And it is such a privilege to be able to relay and the best advice available from people like Peter, Leonard or Maj. And many others as well willing to help the fellow club member. That for me is the essence and the reason we are all banded together here. Fantastic work mate

Going through the pics I could not help not to notice the powder measure and the reloading press. You didn't try to top the horsepower up with some, did ya?

Love big horsepower and big calibres, just can't help myself! lol