258 replies to this topic

[TYREDNGRUMPEE]

right must go and put some butter on my cod liver oil capsule

Mineral or sympathetic?

Alex is an upright lad that doesn't go fer yer evil Oxferdshire Juju practices.

[TYREDNGRUMPEE]

Possible gearbox opportunity here Alex

http://www.carpe-tdm...19

http://www.carpe-tdm...19

http://www.carpe-tdm...26

Edited by TYREDNGRUMPEE, 17 January 2013 - 09:46 pm.

[alexk243]

Well I am already this far in so I think I am past oil additives.

OK, spent a lot of time in the garage troubleshooting. Took a close up video of it cycling through gears, that can be found here.

Also sketched a diagram of where it connects in each gear for my reference (sorry its sloppy) ask if you dont understand it haha.

[alexk243]

Possible gearbox opportunity here Alex

http://www.carpe-tdm...19

http://www.carpe-tdm...19

http://www.carpe-tdm...26

I am following that post now. Were you thinking the whole engine or just the gearbox? Also did you find an answer to if an MKII will fit a MKI?

[alexk243]

Pictures of it in each different gear (as indicated by my finger in the pictures) can be found here

Edited by alexk243, 17 January 2013 - 10:46 pm.

[TYREDNGRUMPEE]

I am following that post now. Were you thinking the whole engine or just the gearbox? Also did you find an answer to if an MKII will fit a MKI?

Yes. Good news.

here

http://www.carpe-tdm...26

I was thinking just the complete gearbox assembly from a Mk2 bottom end would do very nicely.
Just depends on whether "Heavyboned" regards his broken unit as a paperweight taking up garage space or as a bountiful source of cash. His call I suppose.
I can collect at the drop of a hat. Then it's up to one of us (me), collect/dismantle/FedEx.

Edited by TYREDNGRUMPEE, 17 January 2013 - 11:01 pm.

[alexk243]

Also here is a close up of the gears taken off the shaft

From looking at them taken apart you can see that the one dogs that link up when the bike is in 3rd are worn on the top. Signs that is was clearly skipping in third. Hard to tell how it is jumping down to 2nd though.





These two link together and you can see after they were cleaned of oil where they were rubbing when the bike skipped.

So its clear that as the gears skipped more they got worn down making it easier to skip and jump down to second... but what made it skip in the first place?

Edited by alexk243, 17 January 2013 - 11:02 pm.

[TYREDNGRUMPEE]

So I'm taking my time looking at your photos and video, again and again.

And I'll look at them again and again. The operation of these things is baffling sometimes!

I'd look at the condition of the inner bushes that some of the gears freewheel on too.

Bedtime methinks.

[TYREDNGRUMPEE]

Put simply

Looking at the output shaft, when the freewheeling 3rd gear is spat out, the fourth gear and dogs move outwards. This must transfer some impetus through the forks and selector barrel to make the fifth gear and dogs move outwards in the opposite direction in order so that they can engage the freewheeling second gear.

I'd centre all my attention on the OUTPUT SHAFT viz> 3rd gear + 3rd gear central bush, 4th gear + its' selector fork, the selector barrel and detent spring assy where they make contact in these areas and take a look at the 5th gear + selector fork too. Look at the shaft that the selector forks run on.

How are those bearings on the output shaft?

If I were to point the finger at anything on the input shaft it would have to be the central third gear, as it's here where the load is being transferred when it all goes wrong.

I have a question.
Has this engine been split before?

Edited by TYREDNGRUMPEE, 18 January 2013 - 01:31 am.

[alexk243]

As long as I have had it... no, but i bought it maybe 3-4 years ago and with 30,000+ miles on it so who knows.

The 3rd gear connection is the two that I uploaded and that shows where the contact each other. Its clear they are slipping there, but I dont think just replacing those solves the issue.

I'm lost haha so I am going to try and read your post again and see if it makes sense this time.

[Studley Ramrod]

Just spotted a gearbox on ebay USA. http://www.ebay.co.u...=item5aed0de47a

[TYREDNGRUMPEE]

Just spotted a gearbox on ebay USA. http://www.ebay.co.u...=item5aed0de47a

Yep! That's the one. Proving once and for all time, that TDM gearboxes share DNA with London buses.
If you intend to solve this issue with the minimum of fuss and expense then "Buy it now!". I would. Give them a call or email them first. Get a deal.
Kudos Studders.

Something nice to wake up to.

Edited by TYREDNGRUMPEE, 18 January 2013 - 01:55 pm.

[alexk243]

Do you think I also need the selector shaft as well? or just the shift arms and gears?

Also you think the one on ebay is better than the MKII we were looking at?

Edited by alexk243, 18 January 2013 - 05:25 pm.

[TYREDNGRUMPEE]

Do you think I also need the selector shaft as well? or just the shift arms and gears?

I take the approach that it is best not to mix and match. It would be disastrous if the engine were reassembled and the fault remained.
You can see yourself, that even though your gearbox is definitely at fault and we can say what is going wrong, a single point of weakness can't be identified.
I've always sought out a healthy donor unit and transplanted everything.

I reckon the price for new parts off the shelf would likely exceed that of a complete second hand unit and would most likely not solve the problem.
So my preferred approach is to use something that I've been told was fully functional.

[alexk243]

So no selector barrel? Cause the one on ebay is just gears and shift arms

[TYREDNGRUMPEE]

Also you think the one on ebay is better than the MKII we were looking at?

Yes. It looks better than yours (in the photos that are in focus). The price is the same, shipping will be less. You can ask for a guarantee from the guys on your side.
You will save cash, time and grief.
You also have the advantage of speaking the same language.

So no selector barrel? Cause the one on ebay is just gears and shift arms

Ask them. They won't have binned it surely?
If they have you could use it as a negotiating tool.

Good point though.

Edited by TYREDNGRUMPEE, 18 January 2013 - 05:41 pm.

[alexk243]

Yea, I have been messaging him. That one has been listed for a while for $150.

I meant the MKII gearbox from the guy on this forum that was parting out his bike, not mine haha, I know mine is bad.

[TYREDNGRUMPEE]

I meant the MKII gearbox from the guy on this forum that was parting out his bike, not mine haha, I know mine is bad.

Well, he would like £100 ferrit = $170ish. It works ++1. Needs fetching ££££. Needs dismantling. Needs shipping ££££. Needs fingers crossing. Needs reassembling. = Time + Grief. versus ebay option IMO.

Yea, I have been messaging him. That one has been listed for a while for $150.

Phone 'em! Pin them down. Ask 'bout the selector barrel. They will have finished their lunch break just about now!

[Studley Ramrod]

This one would be a better option perhaps.

http://www.gn-moto.c...s-850-tdm-.html

[TYREDNGRUMPEE]

This one would be a better option perhaps.

http://www.gn-moto.c...s-850-tdm-.html

Mais, Je ne parle pas le Havreais. M**de!