HOW HARD IS A TRANS REBUILD

[slickster]

  And how much are the parts and special tools?  I have plenty of time and another bike to ride in mean time, plus I am retired.

[nhmaf]

There are special tools (such as a modified rear gearbox case cover, that is needed for adjusting and refitting the proper amount of shims in the gearbox if you replace bearings and/or shafts.   It requires significant experience - if you've plenty of gearbox rebuild experience already maybe you can do it, but it is the sort of thing that even those of us who aren't afraid to turn wrenches usually send out to the more expert level folks like Anton Largiader and others.   Whereabout are you located - we might better recommend some folks if we knew from your profile where you called home?

A professional rebuild will range in cost from perhaps a low of ~ $400 up to a bit over $600, depending on level of parts that need to be replaced, etc.

[tvrla]

All the bearings, gasket and seals add up to about $100. You'll need a torque wrench that measures over 200 foot pounds, the output flange holder to remove the nut, the flange puller, propane torch, and precision measuring tools to check bearing depth. I spent around $300 just on the measuring tools, though I've heard of using plastigage or other squishable material that can then be measured to determine the free space between bearings and cover.

Just guessing, I'm thinking about $500.

I forgot about the bearings - you'll need pullers to remove them. I use a 20ton press and have special pullers that can grab the bearing even though there isn't much purchase available. Maybe you could have a shop with that equipment do that for you.

The job seems hard the first several times, but once the obstacles are understood (like any task) it gets easier and easier. I'm sure brain surgery seems pretty simple to a brain surgeon. Seriously - it's a job to be taken carefully and methodically. And if it doesn't feel right when it's all back together, be willing to tear back into it.  

[montmil]

Hmmm...

If I'm reading Mike and 'Spokes comments correctly, the investment in tools and parts is just about equal to what an individual might pay to have an experienced professional -insert favored name or shop here- do the overhaul correctly the first time out. That's peace of mind, too.

I love my tools. I also buy specialty tools if there's the slightest chance I may need them a second time. With two Airheads in the shop and me drifting towards adding a third, that's a reasonable investment. But for me to mess with a transmission rebuild, the numbers and stars just do not align.

Should one of my crashboxes ever need a rebuild, I won't even think twice about it.  [smiley=2cents.gif]