05-14-2012, 03:53 AM
I bought a new 03/04 636 motor from a guy in Kansas City who got it from an insurance auction. It looked like it was in nice condition so i took the risk, bought it up and put it in, and after a couple hours of riding i felt "teeth skip"
At first i thought it was my chain on my front sprocket, so i tightened it before the next session and 1-2 hours in, it skipped again. It would only skip during 1st gear clutch ups, and it would happen probably 1/5 times or less. Also occasionally it would skip under hard acceleration, no clutching involved.
I had a show coming up so i had a buddy from sioux city come help me put in new shift forks and a shift drum because he had some spares (from a bike with zero tranny problems) and thats what he thought the problem was. The new shift forks and new shift drum had zero impact on the problem and it still skipped like we hadn't done anything.
I had some people suggest it might be my clutch so i put a new clutch in it and it still skipped. Only at this point ive been riding it for a while so the skipping is becoming more frequent. After a weekend of riding and ignoring the occasional skip it got bad, and it got to the point where it started hopping out of first and went into neutral EVERY CLUTCH UP.
SOOOOOOO.... at this point i did some research on here and i figured the dogs on 1st gear were toast so i dropped the motor and split the cases.
I was expecting to see an obvious problem but i can't tell what is wrong. The dogs don't look like they are worn any more than normal wear and tear. There are no metal flakes or debris in the oil, and i have absolutely no clue what is wrong. I bought a new input and output shaft with all the gears from a mechanic in sioux city which was out of a bike that had no tranny problems and it looks like it has much worse wear than the tranny that is slipping in my bike
Any ideas on where i can start trouble shooting from here? Does the very minimal wear shown in my photos look like it would cause this drastic of a problem? Sorry for the novel but i wanted to give any clues i can.
TLDR; My tranny is fucked and i can't figure out why, ill rain down rep on anyone who can help
Here's pics of parts from the transmission that is skipping:
http://imgur.com/a/JXDqN#1
At first i thought it was my chain on my front sprocket, so i tightened it before the next session and 1-2 hours in, it skipped again. It would only skip during 1st gear clutch ups, and it would happen probably 1/5 times or less. Also occasionally it would skip under hard acceleration, no clutching involved.
I had a show coming up so i had a buddy from sioux city come help me put in new shift forks and a shift drum because he had some spares (from a bike with zero tranny problems) and thats what he thought the problem was. The new shift forks and new shift drum had zero impact on the problem and it still skipped like we hadn't done anything.
I had some people suggest it might be my clutch so i put a new clutch in it and it still skipped. Only at this point ive been riding it for a while so the skipping is becoming more frequent. After a weekend of riding and ignoring the occasional skip it got bad, and it got to the point where it started hopping out of first and went into neutral EVERY CLUTCH UP.
SOOOOOOO.... at this point i did some research on here and i figured the dogs on 1st gear were toast so i dropped the motor and split the cases.
I was expecting to see an obvious problem but i can't tell what is wrong. The dogs don't look like they are worn any more than normal wear and tear. There are no metal flakes or debris in the oil, and i have absolutely no clue what is wrong. I bought a new input and output shaft with all the gears from a mechanic in sioux city which was out of a bike that had no tranny problems and it looks like it has much worse wear than the tranny that is slipping in my bike
Any ideas on where i can start trouble shooting from here? Does the very minimal wear shown in my photos look like it would cause this drastic of a problem? Sorry for the novel but i wanted to give any clues i can.
TLDR; My tranny is fucked and i can't figure out why, ill rain down rep on anyone who can help
Here's pics of parts from the transmission that is skipping:
http://imgur.com/a/JXDqN#1