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Jumping Out Of 4Th


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#1 rcmad

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Posted 21 August 2019 - 09:43 am

Hi, first time i've been back here for ages!

 

So the gearbox on my Mk2 850 has taken to jumping out of 4th under acceleration, does not do it in any other gear or if i'm just bimbling along in 4th. Reckon the dogs are worn.

 

I have a query regarding splitting the cases as the manual isn't clear, what is the minimum i need to remove to split the cases? I reckon i can get away with removing both side covers and the oil cover and then the bottom case should magically come off with absolutly nothing going wrong whatsoever :rotflmmfao:  I'm not planning on replacing anything else in the engine or even looking at it too closely as she runs strong and doesn't use too much oil. Once i've confirmed the issue i'll either replace the bits or drop in a gearbox from a 900, whichever is more cost effective.



#2 wicklamulla

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Posted 21 August 2019 - 09:52 am

Don't tink it's that simple. Don't tink a 900 gearbox will fit. Good luck with it.

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#3 Studley Ramrod

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Posted 21 August 2019 - 09:54 am

And back to reality :lol:  I'd say you'll need to remove pretty much everything.  Some bolts holding the crankcases together are hidden inside or behind engine parts.

I don't think a 9'er gearbox will fit, seem to remember Dappers measuring both 9'er and 8 fiddly boxes and the 9'er was longer.


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#4 dapleb

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Posted 21 August 2019 - 10:24 am

Not that it matters much but is it def 4ty and not turd it's jumping oooot of?

You have a lot of work and expense (gaskets) ahead to fix issue unless it's just a simple gear pedal adjustment issue (unlikely).

9er box ain't gonna help you none.

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#5 fixitsan

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Posted 21 August 2019 - 12:34 pm

It's a strip down of pretty much everything.  There are bolts holding both halves together which are under the barrels.  You'll need a full gasket set (£100-ish)

 

You can get the gear dogs undercut which will solve the problem, or replace the worn ones.

 

I had to replace an output drive shaft which holds one of the gearsets, inside the engine, and it became a full stripdown.

 

It was a problem releasing the flywheel from the crank, which needs to be done so that you can line up the keyway with another mark on the cases. I suppose you could make a mark on the flywheel and stick with using that ?

 

Mark everything you remove with cylinder 1 at TDC and take lots of photos, especially of spring mounted assemblies


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#6 dablik

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Posted 21 August 2019 - 04:18 pm

Oh, thats quite a bit of work i would imagine..


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#7 rcmad

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Posted 21 August 2019 - 08:07 pm

Ah, didn't realize it was that involved, ah well guess I get to see exactly what state the engine is in then, suppose that's not a bad thing really and I was thinking of checking the valves anyway and the engine could do with a kick of paint, lol project creep already!! 😂 I've had my Ducati in bits before this so I'm well prepared, already started with the photos and I've not even got the engine out of the frame yet. Did drop the oil and there's nothing funny going on there which is good. Also pulled both side covers to try and drain most of the oil out before I pull the engine at the weekend. One of the first things I did when I first did a chain swap was mark the position of the pedal, so hopefully it's not that, all the part were right when I removed it earlier. Thanks for the reality check and great advice,Will keep you all updated with progress.

#8 fixitsan

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Posted 22 August 2019 - 12:29 pm

Ah, didn't realize it was that involved, ah well guess I get to see exactly what state the engine is in then, suppose that's not a bad thing really and I was thinking of checking the valves anyway and the engine could do with a kick of paint, lol project creep already!! I've had my Ducati in bits before this so I'm well prepared, already started with the photos and I've not even got the engine out of the frame yet. Did drop the oil and there's nothing funny going on there which is good. Also pulled both side covers to try and drain most of the oil out before I pull the engine at the weekend. One of the first things I did when I first did a chain swap was mark the position of the pedal, so hopefully it's not that, all the part were right when I removed it earlier. Thanks for the reality check and great advice,Will keep you all updated with progress.

 

 

It's probably worth fitting new piston rings. I did rings and bottom bearing shells when i did my gearbox. It only added £60 but meant those parts were renewed


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#9 rcmad

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Posted 24 August 2019 - 02:37 pm

To the front that asked if it was third. Seems you were correct sir. It never dropped out of third but the third gear pinion dogs are worn and the single selector fork has obviously been overheated in the past trying to keep it in third. The rest of the engine appears to be in great shape, piston bores still have home marks and the main / big end bearings look like new. The issue now is that I can't find a third gear for sale anywhere!


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