3rd Gear has let go - gearbox rebuild...

Discussion in 'General 1000RR Discussion' started by highsider, Oct 15, 2018.

  1. tuktuk

    tuktuk Senior Member

    Joined:
    Dec 2, 2015
    Messages:
    1,125
    Likes Received:
    526
    Guy who told me about this issue said it was down to quickshifter use.

    If there is no change in stock gears then I can't see why all years 2008 to 16 wouldn't be affected.
     
    • Thanks Thanks x 1
  2. nigelrb

    nigelrb Senior Member

    Joined:
    Nov 2, 2017
    Messages:
    6,119
    Likes Received:
    2,058
    Cheers tuktuk.

    I always wonder whether quickshifter use under hard acceleration (road or track) might place more stress on components than with clutch changes. In a racing or track situation, I understand there would be more stress, but race terms gearboxes would be stripped and inspected regularly to pre-empt/prevent such catastrophes - or such is my belief.

    As a track rider yourself, how frequently would you dismantle and inspect engine/gearbox? Cheers!
     
  3. tuktuk

    tuktuk Senior Member

    Joined:
    Dec 2, 2015
    Messages:
    1,125
    Likes Received:
    526
    He showed me the gear he'd taken out and said when your banging it up a gear with the quickshifter at high revs, your transferring all 180hp (roughly) to that gear and the thickness of the material isn't very much so they shear.

    I only mess about with the odd trackday so I hope I'm never at the point of needing to strip the box down. Got 11k on mine and it's had a qs on for about 9 of those and I use it constantly.
     
    • Thanks Thanks x 1
  4. hitch

    hitch Well-Known Member

    Joined:
    Jan 27, 2017
    Messages:
    1,190
    Likes Received:
    428
    What about clutchless gear changes?
    I don't have a quickshifter and more often than not change up in a clutchless fashion o_O
     
  5. hitch

    hitch Well-Known Member

    Joined:
    Jan 27, 2017
    Messages:
    1,190
    Likes Received:
    428
    What about clutchless gear changes?
    I don't have a quickshifter and more often than not change up in a clutchless fashion o_O
     
  6. tuktuk

    tuktuk Senior Member

    Joined:
    Dec 2, 2015
    Messages:
    1,125
    Likes Received:
    526
    Yeah that's a good point Hitch. Only difference is the slight roll off so there won't be as much power transferred as being wide open throttle but must still give it a fair whack!

    It's not something I'm worried about tbh. Only gear I won't use quickshifter on is 1st to 2nd, after that I'm too busy holding the bars to give the clutch a grab :D
     
    • Like Like x 1
  7. highsider

    highsider New Member

    Joined:
    Oct 15, 2018
    Messages:
    22
    Likes Received:
    13
    Interesting it is 3rd that generally gives up, not 2nd or 4th. Either 3rd gear is the most used gear on a track, or there is a manufacturing fault or design issue?
     
  8. nigelrb

    nigelrb Senior Member

    Joined:
    Nov 2, 2017
    Messages:
    6,119
    Likes Received:
    2,058
    No. It's more serious than that.

    It's because of the dominant role of the number ‘three’ as a factor in astrological and biological life. The starting point is incontrovertible. The earth is the third planet from the Sun. Its circumference is indisputably 24,900 miles, while the equatorial diameter is 7,900 miles. The circumference is therefore three times that of the diameter.


    The relationship of number three to earth is unique. All things on earth are three-dimensional. There are three stages of matter: solid, liquid and gas; three primary colours: red, blue, yellow; and three components of food: protein, carbohydrate and fat.


    It was on the third day The Holy father created the earth. The birth of Christ was signified by the Three Wise Men. The Lord rose after three days! Jonah returned unharmed from the whale after three days and three nights. Christianity had placed its own reliance on the number three and furthered that with the Holy Trinity: the Father, the Son and the Holy Spirit.


    Not only has Christianity adopted the number three as a figure of worship. So too has Hindi. Its deity Ganesh, is blessed with three right and left arms and three right and left legs. Hindi also recognises ‘Trimurti’; a triad of the gods Brahma, Vishnu and Shiva. These divine instances of the number three are too important to dismiss as coincidental.


    Life itself is dependent on the number ‘three’. A woman will enjoy – or endure – three trimesters of pregnancy. Three trimesters – three times three. What about conception itself, or more particularly, the sperm? The protagonist of life is a three-part cell: the head, containing a nucleus; a middle portion containing mitochondria and a long tail known as the flagellum. The fertilised egg will be identified by one of only three available human chromosomes: XX, XY and the rarer XXY.


    The Third World is often used as a derogatory term for underdeveloped countries or communities. Whoever coined the term ‘Third World’ did so because of the significance of the number three. Consider also the Third Reich. It remains ponderous why the Nazi regime of January 1933 to May 1945 – which professed to be above all – would anoint itself as ‘Third’.


    What about today’s world? Look at literary and entertainment appearances of the number three: Three Blind Mice; Three Little Pigs; Three Stooges; Three Musketeers; Three Amigos; Three Men and a Baby; Three Times a Lady and The Three Tenors.


    Society has been hoodwinked with information from eminent professors down to pop groups. Take the Bee Gees for example – and note, in the main, they were a group of three brothers.


    What about sport? Olympic events of Triple Jump and Triathlon. Cricket - three stumps and the hat trick of three consecutive wickets. Adidas clothing - three stripes. And what do I write to indicate a thought provoking moment?… yes, an ellipsis. Three dots!

    Look around our office and home. How is power delivered? The power point - a three-pin plug.


    Here is clear evidence that it is no coincidence that third gear suffers. It’s a universal conspiracy.
     
    • Like Like x 1
  9. hitch

    hitch Well-Known Member

    Joined:
    Jan 27, 2017
    Messages:
    1,190
    Likes Received:
    428
  10. tuktuk

    tuktuk Senior Member

    Joined:
    Dec 2, 2015
    Messages:
    1,125
    Likes Received:
    526
    I'm guessing 3rd is weaker as this is the one you hear goes pop and Nova have a page on their website dedicated to the cbr 3rd gear.
     
  11. Lozzy

    Lozzy God Like

    Joined:
    Feb 8, 2015
    Messages:
    5,024
    Likes Received:
    2,318
    :rolleyes:

    Screenshot_2018-11-09-22-47-33-1-1.png
     
    • Agree Agree x 1
  12. highsider

    highsider New Member

    Joined:
    Oct 15, 2018
    Messages:
    22
    Likes Received:
    13
    How slow am I getting this sorted!!!

    Whilst faffing, I purchased a replacement engine so if worst comes to the worst, I have a spare.

    Anyway, finally, an update.

    The engine is out now and it is in a workshop engine frame so I can spin it around without damaging it. The last engine I worked on (GSXR) had a bit of damage to it after having it upside down to do some refresh gearbox work as it was jumping out of gears. It's not fully in the workshop frame in the photo - hence looks a bit lop-sided. But it makes life a lot easier.

    [​IMG]

    I couldn't see any damage to the crankcase until I removed the starter motor - and a tooth had punched its way out of the casing. It looked like conrod and gear tooth didn't like to share. But I found a person near me who can weld this up - they specialise in wheel repair and restoration but found out he works on all sorts of restoration - including motorcycle cast alloy casing.

    [​IMG]

    Here's the offending bit of gear with the bit of casing punched out.

    [​IMG]

    Next was to remove the sump with the engine tilted to the side so any shrapnel stayed in the sump. Look what was there to greet me...

    [​IMG]

    Once the sump was off, this was the contents (ignoring the bits on the top-left) -

    [​IMG]

    Although it looks bad, the engine was very clean as far as I can see.

    A lot of the 'bits' have come from the broken 3rd gear grinding against the 3&4 on the main shaft. It's not clear in the photo below but 3&4 has a lot of tooth damage.

    [​IMG]

    So, next on the list is to split the casing and get the hole welded up, which can be done without removing crank, rods etc.

    At the same time, the spare engine is being split to inspect that gearbox as well.

    3rd gear from Nova has been ordered and at least one good gearbox should be on the cards from the two engines.

    After that, the engine is being put back together with an Alpha Shift Stat upgrade (already purchased), so gear changing is more precise.

    Then the engine can go back in.

    The spare lump will get repaired as well - whenever parts pop up. It will remain a spare or will be sold on. I'm so short of space - it might have to be sold...
     
    • Like Like x 6
  13. highsider

    highsider New Member

    Joined:
    Oct 15, 2018
    Messages:
    22
    Likes Received:
    13
    Can anyone recommend a good dealer to purchase the gearbox 28mm and 30mm circlips, please?
     
  14. Barstewardsquad

    Barstewardsquad God Like

    Joined:
    Feb 27, 2012
    Messages:
    5,100
    Likes Received:
    2,287
    Normal ports of call for me are David Silvers or CMSNL, but I have never got to that level of repair, far too scary for me.
     
    • Agree Agree x 1
  15. highsider

    highsider New Member

    Joined:
    Oct 15, 2018
    Messages:
    22
    Likes Received:
    13
    Thanks!
     

Share This Page