minimal ? moderate ? well fook'd ?
Worn Gearbox Cog Dogs ?
Started by
Studley Ramrod
, Nov 30 2012 08:34 pm
16 replies to this topic
#1
Studley Ramrod
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Posted 30 November 2012 - 08:34 pm
Anyone experienced enough to give their onions on the state of wear to the cog dogs highlighted with the red arrows in me pic please ?
minimal ? moderate ? well fook'd ?
minimal ? moderate ? well fook'd ?
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#2
leehenty
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Posted 30 November 2012 - 10:04 pm
are they pitted ? need also to look at the opposite number with which they engage see how they are.
The M18 x 1 shaft thread could do with a gentle clean up too.
The M18 x 1 shaft thread could do with a gentle clean up too.
Edited by leehenty, 30 November 2012 - 10:05 pm.
2002 900 silver,oil pressure switch with brass 90 degree conversion, RG fork protectors. Wilburs custom made rear Shock with remote hydraulic preload and RG shocktube, Wilburs front springs. Scotoiler with a custom made swing arm delivery unit. Silicone radiator hoses.BMW 1150 handguards with Touratech extensions, Carbon Fibre yoke cover and fender extenda, MRA flip screen, Yamaha Engine bars, SW Motech Centre Stand, Kappa wingrack three box Luggage with E21's as option from the K960 boxes, Zumo 660 satnav on Touratech mount, Led Voltage monitor, Baglux tank cover, Clear LED Rear light, Aux LED brake light, Stainless rear axle nut, stainless chain adjusters, stainless wheel spacers front and rear, Probolt Polished Stainless Flanged Hex engine screws, Polished stainless fairing screws, stainless disc bolts. Titanium brake pins front, Probolt Titanium Flanged Hex Front Caliper Bolts & Rear caliper slide pins.<p>Top Sellerie double gel pad seat. Carbon Fibre inner dash and side infill panels. Anodised black alloy swingarm pivot bolt covers and footpegs, Nano II Gear indicator.
#3
Studley Ramrod
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Posted 01 December 2012 - 12:06 am
No pitting Lee, and the opposite number side thingys have hardly any wear at all.
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#4
TinTin
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Posted 01 December 2012 - 10:18 am
Seen a lot worse than that and still in use. Why the shafts & bearings so rusty. Have they been rescued from the Thames.
Edited by yamahasam, 01 December 2012 - 10:41 am.
#5
leehenty
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Posted 01 December 2012 - 11:06 am
They look ok to me if no there is no pitting or chipping which is what usually happens.
I'm concerned about the big open cage bearing though, It will need a thorough clean out before putting it back.
I'm concerned about the big open cage bearing though, It will need a thorough clean out before putting it back.
2002 900 silver,oil pressure switch with brass 90 degree conversion, RG fork protectors. Wilburs custom made rear Shock with remote hydraulic preload and RG shocktube, Wilburs front springs. Scotoiler with a custom made swing arm delivery unit. Silicone radiator hoses.BMW 1150 handguards with Touratech extensions, Carbon Fibre yoke cover and fender extenda, MRA flip screen, Yamaha Engine bars, SW Motech Centre Stand, Kappa wingrack three box Luggage with E21's as option from the K960 boxes, Zumo 660 satnav on Touratech mount, Led Voltage monitor, Baglux tank cover, Clear LED Rear light, Aux LED brake light, Stainless rear axle nut, stainless chain adjusters, stainless wheel spacers front and rear, Probolt Polished Stainless Flanged Hex engine screws, Polished stainless fairing screws, stainless disc bolts. Titanium brake pins front, Probolt Titanium Flanged Hex Front Caliper Bolts & Rear caliper slide pins.<p>Top Sellerie double gel pad seat. Carbon Fibre inner dash and side infill panels. Anodised black alloy swingarm pivot bolt covers and footpegs, Nano II Gear indicator.
#6
Studley Ramrod
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Posted 01 December 2012 - 11:55 am
Cheers Sam, yeah, I think the engine it belonged to musta been left without the side covers on in at some point in it's previous life, it's only the ends that have rust.
Lee, I've just spun the axle and it was a tad rough. Shouldn't be a problem for the intended new owner as he's basically only after the 3rd gear cogs. That said, it may not even be a problem once it's cleaned an loobed.
Lee, I've just spun the axle and it was a tad rough. Shouldn't be a problem for the intended new owner as he's basically only after the 3rd gear cogs. That said, it may not even be a problem once it's cleaned an loobed.
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#7
TYREDNGRUMPEE
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Posted 01 December 2012 - 03:32 pm
Look at this link and be the judge ie. (rounded off is not good)
http://www.yzf600r.c...hp?f=21&t=48251
http://www.yzf600r.c...hp?f=21&t=48251
#8
Matt101
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Posted 01 December 2012 - 03:46 pm
They are no where near that bad on the dogs!! I'll have mine out at some point this week so will know what a bad one looks like.
#9
Studley Ramrod
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Posted 01 December 2012 - 05:31 pm
Cheers mr Grumpee good to know what state they get to when they're failing.
Does anyone know if these dogs can be rebuilt/re-profiled ?
Not very warm out is it Matt ?
So it'll be next weekend, or beyond, afore I get the 3D jigsaw delivered then ? Suits me better if it is actually.
good to know what state they get to when they're failing.Does anyone know if these dogs can be rebuilt/re-profiled ?
Not very warm out is it Matt ?
So it'll be next weekend, or beyond, afore I get the 3D jigsaw delivered then ? Suits me better if it is actually.
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#10
TYREDNGRUMPEE
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Posted 01 December 2012 - 05:41 pm
This will provide a good reference point for TDM owners. I have had to replace three EXUP gearboxes that would jump out of second gear.They are no where near that bad on the dogs!! I'll have mine out at some point this week so will know what a bad one looks like.
The wear on the dogs and recesses was barely perceptible, but I was able to cure the problem in every case.
ThisCheers mr Grumpee
Thanks Studders. I liked the commentary the author gave too. These are defo fooketyfooked
#11
Studley Ramrod
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Posted 01 December 2012 - 05:51 pm
Ha yeah, I read the commentary but couldn't help thinking some pocket-rocket clutchless gearshifts mighta also been a contributing factor.
How did you go about curing the problem ?
How did you go about curing the problem ?
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#12
tdm850rider
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Posted 01 December 2012 - 07:00 pm
Ha yeah, I read the commentary but couldn't help thinking some pocket-rocket clutchless gearshifts mighta also been a contributing factor.
How did you go about curing the problem ?
Goes straight from 1st to 3rd.
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#13
TYREDNGRUMPEE
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Posted 01 December 2012 - 08:03 pm
Biting the bullet and replacing three x 2 complete shaft assemblies that I knew were reliable, as I didn't want to have to go back inside again.Ha yeah, I read the commentary but couldn't help thinking some pocket-rocket clutchless gearshifts mighta also been a contributing factor.
How did you go about curing the problem ?
A parts guy at Fowlers was feeling generous and had a load of surplus rotary Norton F1 gearboxes = FZR1000. Super cheap at £125.00 complete. Should have bought the lot. Doh! Those were the days. Trevor Nation, Rocket Ron.
The others I sourced from blown ThunderAce engines, the gearboxes of which were much improved.
I recommend you replace the entire shebang when it comes to second hand kit.. Shafts,selector barrel,forks as they are a matching fit.
I don't know whether dogs can be rebuilt, but I'm guessing that given the stresses and that everything has to be a perfect match, then odds are they can't, economically.
If you could find a totalled/lo-mileage/spares/repairs TDM with a history and keep the collection/total costs below £150-£175 I'd take that route.
#14
TinTin
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Posted 02 December 2012 - 10:47 am
The ones on the pink towel are shagged but I still say Studleys are just normal wear and tear & have life in them yet.
#15
TYREDNGRUMPEE
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Posted 02 December 2012 - 04:22 pm
If he knows they worked before they were removed from the crankcase then I'd agree.The ones on the pink towel are shagged but I still say Studleys are just normal wear and tear & have life in them yet.
Like I've said earlier, terminal wear on an FZR gearbox is invisible compared to the example here and Studders unit.
I wonder how bad it can get on a TDM before it does the jumping out of second thing?
That's why we need photos as soon as a faulty gearbox is removed.
#16
Studley Ramrod
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Posted 02 December 2012 - 07:07 pm
Is it possible that the FZR also had a bent fork selector contributing to the problem ? It'd explain why they slip but don't show much wear. 
But yeah, ideally a photo of an 'only just started slipping' cog would be good.
But yeah, ideally a photo of an 'only just started slipping' cog would be good.
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#17
TYREDNGRUMPEE
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Posted 02 December 2012 - 07:37 pm
Or worn channels in the gear selector barrel. Hence best policy, get a complete good'un to make allowances for wear. (Wear)ever it may be in the system.
Actually, now that I've mentioned it, you haz jogged my memory. My main issues in at least 2 cases were with the channels in the gear selector barrel. This just goes to show that a problem could be caused by wear at any point in the system. When you get there, I should scrutinize every component, like your bank balance depended on it.
Actually, now that I've mentioned it, you haz jogged my memory. My main issues in at least 2 cases were with the channels in the gear selector barrel. This just goes to show that a problem could be caused by wear at any point in the system. When you get there, I should scrutinize every component, like your bank balance depended on it.
Edited by TYREDNGRUMPEE, 02 December 2012 - 07:46 pm.
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