Uh oh... surgery time (bike, not me)... Few pics - Ford Powerstroke Diesel Forum
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Old 04-28-2013, 06:20 PM
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Uh oh... surgery time (bike, not me)... Few pics

Well for the past couple months now my bike has been getting rather picky about staying in 3rd gear. It wasn't 'that' bad, but it has been getting progressively worse, so finally had to tear into it and get it all fixed up. Got all the parts I needed to fix it, and had a little time since we weren't riding the following weekend (went to the GNCC races again that weekend!), so decided it would be a good time to tear it apart

Went pretty quick.... I rode it to work thursday, rode home (carried all the tools I'd need in a backpack and tankbag), got home a little after 6pm, got started on it about 6:30 or so, and it was out and ready to go by 8:30. Not too bad.... coolant was still steaming when I drained it and motor was still warm when I loaded it into the back of my car, LOL. The little A-frame idea worked like a champ! Hard to see in the pic but the whole bike is actually hanging in the air. I'm not gonna lie though, I really do wish I had a cassette style transmission that didn't require pulling the motor out to do this, lol



Took it into work with me friday morning to tear it down. Boy was she dirty outside... the rural roads I ride on around here are so much dirtier than other places I used to live. Had to do some scrubbing on the outside for sure. The valve cover gasket was also leaking a little bit too so that didn't help any (it's original.... got a new one)



Inside though... nice and clean. Oil still nice and clean too for having almost 6k miles on it. Bike and motor have 256,000 miles and pretty much all original... never rebuilt it, just had this same trans issue once before and that's about all I've done internally (I'm the original owner, bought it with 3 miles on it). Also keep in mind this is a high revving motor too, redlines at 14,200 RPM and has 6 trackdays on it as well. Not too bad! Oh yea it's a 2004 Honda CBR 600 F4i







Original clutch still hanging in there and looking good (256,138 miles)



Once again..... squeeaaaakkky clean inside, always makes me happy to see. Regular oil changes FTW!





Bottom end looks brand new







And here would be my problem..... gear dogs on 3rd rounded off, and of course 6th too since it meshes with 3rd





And got the shift fork a lil bit too



Got the new gears put in and trans back together.... guess I have my work cut out for me monday when I go back, haha. Then I've gotta do a valve adjustment as well.... fun fun. Should have her back together and running again this next week sometime and back to our usual weekend rides next weekend




Still don't have it back together just yet, but just cuz I'm waiting on a few gaskets and o-rings that I had forgot to order beforehand (or didn't know I'd need). Had to get a valve cover gasket (was still original.... found leaking just a little bit), o-rings for the oil pick-up and pressure relief valve, and the o-rings that go around the spark plug holes on the bottom side of the camshaft hold down plate. Hopefully they'll be in early this week and I can get it all back together. Other than that everything else is done... trans is fixed and cases back together, valve adjustment done, just waiting on the gaskets and I'll be set

Anyways, a few more pics....

Original clutch still measures well in spec (2.4mm)







Top end like brand new.... literally looks like zero wear on the cam lobes, journals, thrust bearing, etc







Certainly can't complain.... Rotella T6 has done me well!
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