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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Drivetrain » Transmission: Breather, Gears, Dogs, Forks, Bearings » Transmission gear undercutting and assembly « Previous Next »

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Jgcable
Posted on Tuesday, December 13, 2011 - 03:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I need to know if undercutting a transmission is necessary. I have a 2003 XB9R that had a locked up transmission. I split the case and I found damaged gears, a bend shifter fork tube and damaged shifter forks. Many of the gears look ok but several are damaged. Case is perfect. Anyway, in addition to buying a bunch of very expensive gears I have been told that magnafluxing, undercutting and proper assembly are crucial. Again, this is a fairly expensive process. I am not a racer. I am just repairing what needs to be repaired but I want to do it right because it was a pain in the butt removing and splitting this case. I feel magnafluxing is a definate because I can't tell if a gear might have a hairline crack in it but what about the undercutting and assembly. Mark at R&D was very informative but between buying the new parts and the labor charge I am looking at around $1000.00 easy. The magnafluxing, undercutting and assembly is $500.00. I also have to buy between 3 and 4 gears, 2 shifter forks and a fork shaft. The gears seem to run around $125.00ea new. The forks are around $50.00ea. Just asking for some advice.
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