Transmission Work on yr 2000 1150.

[Colban]

It appears i may have to perform some serious work on my clutch/gearbox and/or my final drive on my 52K miles 1150.
First problem..i have a noisy 4th gear.Not serious,ie wont fall apart as its had the problem for a long time.
I would also like to replace the 1st gear with the adventure ratio.Has anyone done this?,is there any reason it may not be possible?,and what would be the cost for the 2 (i presume) pinions?.
Second problem. I have a loud clunk when setting off from standstill.Other bikes don't have it so i don't believe its a "they all do that sir" noise.
Once again,it has been a feature of the bike for a long time now and it appears to be the drivetrain taking up excessive slack.
Does this sound familiar to anyone or does anyone have any fault finding suggestions to try and isolate the problem to a particular area before the stripdown?.
I will also probably replace the clutch while the gearbox is off.
I have a reasonabe tool kit for this work,but no special tools.
It looks like i may have to buy gearbox alignment pins and a clutch centre alignment tool unless there is a kind person out there who can lend them to me in return for a beer.
Your comments/ideas would be appreciated.Thanks in advance,Col.

 

[beermonster]

I would say avoid doing this unless you have too! Mine engages first with a healthy? clunk, and has always done so.

As for alignment pins, you can make your own from old bolts (M8) and you do not need an alignment tool. It's possible to bodge a substitute or align by eye.

Plenty of info on this site and Adv rider if you are still determined to fiddle.

 

[hodge1150]

gearbox alignment pins - M8 x 120 and cut the heads off, deburr (remove sharp edges) and hacksaw a slot in the non threaded end so you can screw them in. The gearbox was a bugger to get off it sticks at the location dowels between gbox and engine, loads of penetrating oil and muscle, if levering BE GENTLE.
good luck
Hodge

 

[Colban]

I would say avoid doing this unless you have too! Mine engages first with a healthy? clunk, and has always done so.

As for alignment pins, you can make your own from old bolts (M8) and you do not need an alignment tool. It's possible to bodge a substitute or align by eye.

Plenty of info on this site and Adv rider if you are still determined to fiddle.

Believe me,i dont want to fiddle,but there comes a time when you have to.
The noises have been going on for about 5 years now and its not getting better.
As to the loud clunk,its not when you put it into gear.Its when you are feeding the clutch it to pull away.It seems like wear/excessive backlash in the geartrain.

 

[beermonster]

Ok

You may find these links useful;

http://www.advrider.com/forums/showthread.php?t=52149

http://www.advrider.com/forums/showthread.php?t=47332&page=1&pp=15


You may want to check your drive shaft if getting play from that area, might save you removing the gearbox.

Simon