| Author | Message | ||
     Jgcable |
I have the entire tranny apart on my 03 XB9R and I have the service manual. Its next to impossible to figure out which gears are what. None of them are marked and some are very similar. I have some damaged gears but I don't know what to order because I can't figure out which ones they are. Also, based on the service manual I would never be able to figure out how to put the tranny back together. The service manual shows an exploded diagram but its not detailed. Heck.. it doesn't even show some of the small piece parts. Can anybody help me on this? | ||
| Jramsey |
Parts catalog may help better than the service manual. Tuber parts books have detailed descriptions and show location/placement. | ||
| Ochoa0042 |
is there not a page where it shows you the drive-path of the selected gears? ie: from 1st to 2nd these gears shift over, enabling 2nd gear drive..? you can go at it manually: turn the shifter drum to 1st gear and shift up through to the gear that you are wanting to know about The parts manual will have an exploded picture of the transmission | ||
| Jgcable |
my case is split, the entire transmission is disassembled and on my bench. All the gears, shafts forks and clips are all separated. I have the service and the parts manual out and they show detailed pictures but they aren't detailed enough to know which gear is which. Some of the gears are extremely similar. The only items that have part numbers on them are the forks. I can't even order new parts because I don't know what to ask for. | ||
| Ochoa0042 |
reassemble and figure it out, you going to have to sometime. what are the ratios of each gear when shifting? once you know the drive-path, count teeth to figure out which of the similar-gears to use to match the ratio for when the transmission is set to that gear. | ||
| Ochoa0042 |
and damnit, you should of taken more detailed steps disassembling!!!  | ||
| Ericz |
I'll be taking some pics of engine parts tomorrow and I'll shoot some of my trans so you can see how to arrange the gears. | ||
| Jgcable |
Thanks alot. I thought the gears would have stampings on them or the service manual would have better detail but it doesn't. Also, the spline that goes through the case and holds the clutch on is still attached to one side of the case. Is it pressed in? I tried tapping it with a rubber malled and it won't come out. | ||
| Ericz |
Here is a shot of both the mainshaft and countershaft gear arrangement. THE MIDDLE GEAR ON THE COUNTERSHAFT IS SHOWN INSTALLED BACKWARDS! Sorry  I quickly slipped the gears on the shaft to take the shot. The shift fork groove on third gear should be on the 2nd gear side and not the 1st gear side. Mainshaft Tooth count: 1st-20T, 2nd-30T, 3rd-34T, 4th-37T, 5th-42T Countershaft Tooth count: 1st-32T, 2nd-33T, 3rd-29T, 4th-26T, 5th-25T   | ||
| Ericz |
Both the main and counter shafts are pressed into the bearings on the primary side. The transmission shafts should stay with the left crankcase half when you split them and you have to press the shafts out of the bearings to remove the transmission. Be sure to follow the service manual instructions for both removal and installation to prevent damage to any of the transmission parts! |
