Gearbox overhaul

[RK6]

That's me on a mission to get my bike back into tip top condition.
I've got a shopping list as long as my arm of little odds & sods & No 1 (the only big one) from the list is now in the bag!

2003 complete gearbox in 'as new' condition from Fleabay for £185.00 - BARGAINTASTIC!!



Recently read a thread on PSB (The Aussie one) about a guy doing an overhaul on his gearbox with replacement parts & it looked like an epic job from start to finish!!

There seems to be only 2 options for getting at the gears on an 03 R1 to do this change over.

1) Strip the bike down, remove the engine then flip it over to gain access from the sump

OR

2) Flip the bike upside down, hang it from the rafters by rope & gain access from the sump without having to strip the bike... (Can you imagine the possible FAIL scenario's)?

So yeah, I'm considering giving this a bash (mainly because I can't think of anywhere to send it for the work to be done).

Can anyone think of somewhere that would be able to do a proper job of sorting this out for me?

Any help or advice would be greatly appreciated!

[coullstar]

engine out, not as bad as it sounds.

[Zathos]

Team Abz bikers have done rebuilds before, but you need a good working environment and have to be prepared for the time and effort involved. Do you have full sets of tools and the space to strip down the bike?

Where the professionals will take hours, you will take days or even weeks to achieve the same task.

Having said all that I'm up for giving you a hand mate....

[Zax]

Phone up chap at highland. he can give the bike a tweak when he is in the engine and set it up on the dyno.

Rowan
You are concidering doing this in a garage that has no light , or power with little or no tools and you struggled to get a set of cans off your last bike . get a price from chap.

[al]

JT52 is the chap to talk to!

[Zax]

As Big Kneed Al (master of the emergency stop & "stand up" comedian) says Steve has changed 2 gearboxes on R1's now he is certainly the person to talk to locally.

[RK6]

Phone up chap at highland. he can give the bike a tweak when he is in the engine and set it up on the dyno.

Rowan
You are concidering doing this in a garage that has no light , or power with little or no tools and you struggled to get a set of cans off your last bike . get a price from chap.

I have a possible place to do the work as my garage is useless but even still you're probably right enough in saying I should at least talk to Chap.

Have you got his contact details per chance?

Was kinda wanting to try the strip down just for the experience (never stripped a 'big' engine before).

EDIT: Got Chap's email address from his webpage, we'll soon see what he says.

[CBRXX]

Engine out flip it upside down pull off the bottom replace bent/bust-up bits put back together chuck it in the bike. you supply the beer I'll supply the pointing finger and a warm garage with light, power and tools if you can be arsed bringing the thing out to mine
Could be done in a day if there are no fk ups but the will be so bargain on two

[RK6]

Engine out flip it upside down pull off the bottom replace bent/bust-up bits put back together chuck it in the bike. you supply the beer I'll supply the pointing finger and a warm garage with light, power and tools if you can be arsed bringing the thing out to mine
Could be done in a day if there are no fk ups but the will be so bargain on two

Now that is tempting!

Just realised that there's a bloody postal strike so I wont get the gearbox till that clears itself up.

How's the car by the by?

[CBRXX]

Just realised that there's a bloody postal strike so I wont get the gearbox till that clears itself up.

How's the car by the by?

Its clean and it runs but still leaking oil haven't had the time or inclination to pull the head of it yet, will probably retorque it this weekend and recheck the fluids to see if that does anything cause there's no contamination of the oil or coolant atm, seems to have picked up electrical gremlins and the gearbox is hell of a slow engaging reverse but could be to do with lack of use and fluid draining from torque converter or valve bodies if it even has them on that box haven't got round to checkin.
So all in all its just making a nice garden ornament just now

[RK6]

Just realised that there's a bloody postal strike so I wont get the gearbox till that clears itself up.

How's the car by the by?

Its clean and it runs but still leaking oil haven't had the time or inclination to pull the head of it yet, will probably retorque it this weekend and recheck the fluids to see if that does anything cause there's no contamination of the oil or coolant atm, seems to have picked up electrical gremlins and the gearbox is hell of a slow engaging reverse but could be to do with lack of use and fluid draining from torque converter or valve bodies if it even has them on that box haven't got round to checkin.
So all in all its just making a nice garden ornament just now

Fair enough dude! Glad you got it running.

Winter's closing in so I'm sure you'll manage to beat it into submission at some point soon!

[steve]

JT52 is the chap to talk to!

he has already asked me mate

nae worries rowan its easy(ish) , i will help you out nae worries

gimme a shout an we can sort out details etc

[al]

Watch out for those exhaust header studs!

[steve]

Watch out for those exhaust header studs!

hmmm yeah they can be fickle little sods eh

[RK6]

Watch out for those exhaust header studs!

I have a history with R1 exhausts as Dave kindly pointed out already.

Here's hoping this system hasn't fused itself together like the last!

[Newbus]

Watch out for those exhaust header studs!

hmmm yeah they can be fickle little sods eh

#
Mmmm sure there is a great guy on this site with great tool for exhaust studs .

Biggest job about doing repairs on your own bike is getting over the fear of starting doing it.
Check out what if any special tools you will require .Usually once you get started the jobs are
easier than you think.

Usually takes me weeks to pluck up courage to do jobs but once i get started they are no problem.

Good Luck

[CBRXX]

Watch out for those exhaust header studs!

Normally easy enough to remove snapped ones when you have the engine out and plenty of access

Tryin to get them out in a car with a big engine, intercoolers, AC condensors, piping all over the shop and a relatively small engine bay on the other hand is a right PITA

[RK6]

Watch out for those exhaust header studs!

Normally easy enough to remove snapped ones when you have the engine out and plenty of access

Tryin to get them out in a car with a big engine, intercoolers, AC condensors, piping all over the shop and a relatively small engine bay on the other hand is a right PITA

You wouldn't be referring to a certain German car there would you?

[CBRXX]

Watch out for those exhaust header studs!

Normally easy enough to remove snapped ones when you have the engine out and plenty of access

Tryin to get them out in a car with a big engine, intercoolers, AC condensors, piping all over the shop and a relatively small engine bay on the other hand is a right PITA

You wouldn't be referring to a certain German car there would you?

Nah the cavernous bay in that thing is the very heighth of luxury you could put up a hammock and still work away in there! Replacing turbos on cars designed by the nation of people who came up with IKEA flat pack furniture, now theres a challenge

[RK6]

Replacing turbos on cars designed by the nation of people who came up with IKEA flat pack furniture, now theres a challenge

Unlucky!