[davidmizak]

I was showing my dad how to do a clutch up wheelie on his 04 r1. Master link came out, chain popped off in mid wheelie doing about 80mph. I pulled in the clutch immediately, and hit the brakes. Went and got the trailer and hauled it back to the house.

Pulled it inside and took the sprocket cover off. The chain was sort of wedged in there between the sprocket and swingarm. Pried it out, started the bike. and put it in 1st. Front sprocket and the shaft has a nice wobble to it.

After a few seconds of spinning. It stopped (locked up) and the bike cut off. Tried starting it a few more times. As soon as you let off the clutch. It cuts off. Let off the clutch kind of slow, you can see it wanting to spin, but then cuts off. Oh yea and it won't go into any gear above neutral, only neutral and 1st.

We tried rocking the sprocket back and forth until it finally came free again. Started the bike up. Put it in first. It spins, and sounds like crap. and it has a nice wobble to it.

Soooo, whats the damage. New tranny? gears? easy fix?. He's a mechanic. and we're both mechanically inclined. We have the extended service manual and the tools. Just need some expert advice!

 

[davidmizak]

ok thanks for the advice. we are going to tear it down wednesday. and definitely post some pictures once we get it all apart.

 

[davidmizak]

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.

.

 

[davidmizak]

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.

 

[davidmizak]

Okay, we got the water in the oil problem taken care of....and after taking the engine out a second time because we had no sixth gear we found out we were missing two washers on the transmission. Got the bike back together..again..and amazingly with all six gears. Now the only problem is, it idles irradically. I adjusted the idle to around 1200 rpm, and adjusted the throttle cable free-play to spec. Seemed to be doing good but when riding home the other day it started cutting out on me. Then it would either cut off at red-lights or rev really high. It seems like it starts after it gets relatively hot. Any suggestions on what I possibly missed, or did wrong and how I can correct it?