Good luck on your mechanical journey Grover. Perhaps you can entertain/educate(like B_M did) us w step by step documentation pics.

Forgottenone1227 wrote:
Damn you got more guts than I do to tear into the heart of this beast. Goood luck and make sure you have a good manual and takes lots of pics of the tear down so you know where everything goes when putting it back together!

vmaxmercer

yep the man got BALLS to take that on

Now i see why.. Good luck in finding the issue and gettin' fixed..

IF you come and see your buddy in Denton, you better bring the BEAST or nuttin' @ All..

Good luck!

Well gang, progress is being made. I think I may have found the problem and it's either bad material in the 2nd pinion gear or something got in there and chewed up a few of the teeth. The strange part is, it's only like 4-5 teeth on only this one gear. It seems to me that if something got in there, it would have gotten into more teeth in more gears.

Here's the photo album of the tear down.

Tear Down for Transmission Repair

More importantly, here are links to some videos I made showing what I think the problem is.








I welcome your input before I start ordering parts.



- Grover

Grover,
Did you inspect the gear that meshes with the gear that you are going to replace in the 3rd video? I'm thinking that there might be something wrong with that gear that could be causing the problem.

I did Hammer.

I cleaned every tooth with a sponge Q-tip (no offense Q ) I didn't see anything wrong with the teeth on that gear. It actually meshes with the large gear I show in the second video. I am still considering replacing it because of the small wear/chips I see on the edges where the 5th pinion gear fits into it.

I would rather replace more than necessary while I have it apart. I would hate to get it all back together and still have the same problem. So far my parts list is pushing $900 not including a new battery that I need to order from Tim.

Anybody know how to contact Oliver? I sent him a PM but he hasn't been on here for 2 weeks. I'd really like to order my parts from San Jose Yamaha because the dealers around here are horrible to deal with.



- Grover

The center video shows your problem. It is the same as my problem which was caused by the shifter detent bearing. Check the bearings of the shifter detent. On mine the race had broken and allowed ball bearings to come out. This in turn wouldn't allow 1st or 2nd gear to fully engage, and under hard acceleration would slip (as yours shows happening). The chewed up gear is from a combination of shavings getting mashed between 2 gears and the violent shock the teeth were taking everytime the dawgs allowed 2nd to slip. You're on the right track, just be sure & replace any worn gears and double check every bearing, clean & flush well..
Good job on documenting w/pics & videos.. Thanks

Do NOT SCREW AROUND WITH ANY WORN GEARS! REPLACE FOR EVEN THE SMALLEST OF NICKS OR PROBLEMS!
Mine was done at around 4000 miles, and afterwards made numerous runs at the drags and survived countless burnouts that included snapping a driveshaft! 13k when I sold it and tranny was smooth & quiet as a mouse..Bad_Max wrote:

No_Max wrote:
So this is the second bike with this problem. How many more out there?