04 Transmission help!

prolly output shaft.. been there done that.. i have bent 2 output shafts. thats where wobble comes from. stock is suppose to have runout of .004. for each shaft. .004 if one is tweaked and .004 on other.. thats .008.. there is only .006 in between 2 shafts(lash). motor has to come apart. there maybe other problems. on 04 the output shaft comes with that bearing.. u cant get bearing separate....also why damn thing cost like $170. my first one was bent alittle too much from factory. 1200 miles on it and had it replaced. 2nd one was my fault. getting bike ready for race and started it up, revvig it up checking something... blipping throttle my elbow touched horn button..which is airshifter and it had air and was turned on...at 10k rpms it put bike into 2nd gear, motor died with sidestand down, but it shredded chain, luckily bike didnt take off and destroy itself. put new chain on it, rolled it around and chain went tight to loose. pulled cover off and u could see wobble in output shaft. like 1hander sugguested...i wouldnt run it anymore till u get it apart. no telling what else damage could be done.

u could get it out and send it to R&D motorsports and have him check it. or have it undercut while u there. drop motor and post up pics...sure we can help with getting u in right direction.

ok well we almost got the transmission out. we were short one tool, so definitely going to finish up tomorrow and take better pictures of the transmission.

but so far from what we can see, '2nd wheel gear' and '2nd pinion gear' are destroyed. and the drive axle is definitely bent. there were metal shards from the broken gears in the oil pan and all on the inside of the tranny. is this going to damage other stuff? are we going to be able to clean all that metal debris out?

also the block is cracked where the stator goes. oil was leaking from there. i guess the chain slapped it pretty hard before it got wedged in there. hopefully jb welb can fix this or something. i don't know. any ideas? i guess we really did a number on this one.

i'll get more pix up tomorrow evening...







yea it's in the kitchen.



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ouch.. best bet is take it all apart and put in parts washer and clean hell out of it... then clean it again and again. metal will get in small places. take head off and everything out. no way to clean it all when part of motor together. as for crack..u might get away with JB weld it. its not structural, so u can try it. even crank... u need to run it in parts washer... its like big oil tube.. oil flows thru it.. so u need to wash it out several times. if even 1 spec of that broken debris is left in motor and goes thru bearing.. it can spin bearing, and spit out parts in motor. dont take that chance...its only few bucks for gaskets... hell all u really need is basegasket.. the headgasket u can split in 2, and copper coat it and reuse one u have. so all ur out pulling rest of motor is gaskets. and dont reuse rod bolts. they are 1 time use only. order some new ones. dont cheap out on something like this. do it right 1 time....so u dont have to do it more than 1 time or have to get new motor if it spits its guts out.

so we ordered all the parts. probably spent no more than $400 on everything. had to get a new sprocket, chain, gaskets, seals, found a transmission on ebay with 4k miles on it, in perfect condition for $100, and other random parts that we needed.

Didn't have toy much trouble tearing the engine down, went pretty smoothly. 2nd gear and 2nd pinion gear were just torn to shreads along with the drive axle being bent. The inside of the case had nicks here and there, but nothing too serious. The engien block was busted, where the generator goes. Put some JB weld on the outside of that, and it seems to be holding up well.

I will tell you, it PAYS to be organized, and that is something we are not. The alcohol didn't help either. We had parts all over the house, and it seemed like every time we were missing a part, it was a washer. We even had to wait a few days, because we had to order a part that we couldn't find.

But we got the bike put back together, even had a guy repaint it for $100, since we had it all apart.

--NEED HELP--

Now the only problem we are having is there is water in the engine somewhere. You can see a milky looking color in the site glass. First we found that one of the seals fell out of the water pump, replaced it. Still the same thing. The oil has been changed FIVE times (we get oil for free from my dads shop) and it still has that milky color to it. I'm sure we're just overlooking something...

What else can we do. Pleeeeeeeease don't say we have to tear the engine apart again, I don't wanna do that for a long time.