New R65 owner with gearbox out need Help!!!

[nhmaf]

I think we all learn something with these community diagnosis sessions - sort of
like the Socratic method cafe's that are opening up here and there, for people who
want to have an educational discussion !

I'm adding this to my growing treasure trove of useful bits of motorcycle troubleshooting knowledge !

[Justin B.]

Some pics of the offending part would be nice for the archives...

[raygun]

there is a pic at this link that looks identical to the one I pulled.
http://www.largiader.com/tech/airtrans/

[thrang]

http://homepage.sunrise.ch/mysunrise/joerg.hau/mot/gearbox.htm

Good web page is Jorges I followed his note pulling down the bimbo's box. Just got to to put it back together once I saved some pennys up

[raypond]

G'day Ray, Last week I finished rebuilding the gearbox on my '86 R65 (new bearings, seals and springs). I've never had a gearbox apart before but with Joerg's page (which was mentioned elsewhere), Clymer's manual and advice from people who had actually looked inside a gearbox before the job went surprisingly well.

Except........there was some evidence of a bearing spinning in its housing in the rear cover so I was advised to used one of the Loctite products to hold the bearing in place. With the cover heated with a hot-air gun, shims in place and all looking good I put the cover on. About halfway on the Loctite grabbed. It certainly wasn't going to come off again so there was nothing to do but to keep going and try to pull it down with the 8 screws around the edge. I wouldn't have believed it but it is quite possible to snap that rear cover clean in half. It was even, I was tightening in the approved criss-cross fashion and I wasn't really leaning on the Allen keys. With no warning it just went 'snap'. The two halves came off again quite easily.

Luckily a second-hand cover was cheap ($88, Munich Motors) and on the second attempt (no Loctite) it all went together smoothly. The gearbox is now fabulous to use. I would advise against using any bearing retainer-type product when re-assembling.

Cheers,
Another Ray

[airhead]

I would most totally concur Ray, don't use any bearing retaining compound on any of the bearings in the box, your adviser was wrong. Those bearings do move slightly in their bores when everything heats up and helps them find their natural centres, even with shimming. Sometimes the galling marks (black marking) in the alloy bores are from that movement. Unless the bearing falls into the bore with little or no effort, install it as is.

BTW, where in Oz are you? You mention getting a spare back plate from Munich's, and though I know they mailorder, it seems like you had it all done in a very short time so do you live local? I live only a couple of K from Munich's.

Bill.......................;-)

[raypond]

G'day Bill,

I'm in sunny Beechworth in North East Victoria about 40km south of Albury. I'm pretty impressed with Munich Motors (hello Bruce) and, indeed, Australia Post. Generally three days from ordering to arrival at the Post Office here. Sometimes two. Not bad for about 3,500km. Most parcels cost $9 postage.

For what it's worth - the gearbox overhaul kit they sell includes all six bearings, all seals, the nylon selector roller and all the selector springs for about $330.

Cheers
Ray