2nd Gear Replacement Project

[loboboy]

Hello guys. I finally decided to dive in head first and get this thing taken care of. Parts are on order and I am in the process of tearing it down. After hearing form Dustin at APE that they are 4-5 weeks out for back cutting 2nd I figured I had better get to work.

So here is the start, removing engine. I could not have done this without KS-Waterbug loaning me the engine mount removal tools. Thanks Sonny I really appreciate it.
I didn't go in to detail on how to remove the engine since that is really the simple part of this project. After getting the einge removed I started in on the removal of the side covers, including the stator or generator, starter and starter clutch cover and the clutch itself. This took me all of about an hour to remove all of the covers and I am about ready to start removing the poil pan and split the cases open. I will keep up with the pics and give you all a general idea of what is involved as I can.Here are some pics and let me know if you have questions.
I'm not good with step by step so please be patient with the project.

looks like I need a new clutch as well.

 

[Big Red]

LOBOBOY, You are definately a hands on kinda guy!

 

[S-R Racing]

The experiance you are about to get will pay you back 100 times what your saving on this job alone. Best of luck, take your time,and you'll be back on the road in no time

 

[GoldenChild]

 

[loboboy]

thnaks for the support guys, I have been working on bike engines for quite sometime just never taken on a inline 4 4stroke engine. Most of my experience is with 2 stroke stuff. I have a manual and the proper tools so I can do just about anything, if not then my schooling and the last 18 years in aircraft have been for nothing. LOL

I will keep this post updated with pics as I go so some of you can see what it takes.

 

[BusaWizard]

 

[thepushercg]

 

[Rayabusa0818]

 

[loboboy]

well I think I found the culprit to the problem look at this shift fork.  

 

 

View attachment 1265515

 

[megawatt]

OOOOOOOOOO those marks, look like they don't belong. How did 2nd gear get damaged? Were all miles put on by you?

 

[loboboy]

actually no it was not missed shifts, for the limited amount of wheelies I actually do, just from habit of riding wheelies on the 4 wheeler, I hold too much pressure on the shifter while still on the throttle therefore causing the damage you see here. Once I bent the shift fork it did not fully engage 2nd and started slipping out of gear.
If I had not done this 2nd gear would be just fine right now.

So moral of the story for me is no more wheelies, plus I want to concentrate on track days and stop doing so much squid chasing on the street.

I have contemplated due to time constraints I may just replace the gears without the backcutting so I can get the bike back together and start scheduling some track days. If I was a drag racer I would go ahead and get the backcutting done. Plus I may end upmoving onto a 2008.

APE is talking 4-5 weeks in shop for the backcutting and that just does not work into my schedule, plus I don't want the motor sitting open for the period of time. I plan on putting the motor back together next weekend since I already checked stock on the parts and they are ready to ship.

 

[BusaWizard]

A little wear.

 

[NightCrawler]

I had my tranny undercut because I thought my 2nd gear was gone. Come to find out it was my shift fork.

 

[joseph717]

I'm working on the same thing, pulled out second gear to get it undercut, and have a question...
how did you reinstall your pistons into the cylinder?? I'm stuck on that part.. it's hard to compress the rings, and get the cylinder head on at the same time... do you have any tips/tricks on getting it back in???

 

[omslaw]

Heh - I ran into this last year when putting my engine back together.

You need to get yourself a couple of low-profile ring compressors. They also have to be the type that you can 'separate' to remove them once the piston is inserted into the cylinder. Also make sure you have a copy of the Service Manual - it details the process fairly well.

I picked up a couple of these made by Lisle Corp.

Next, get a helper - it worked out much easier.
Move two of the pistons to TDC and install the ring compressors.
Slide the cylinders on.
When the rings are in the cylinders, remove the compressors.
Now while your helper is holding the cylinders, rotate the crank to bring the remaining 2 pistons to where they're just ready to insert.
Install the ring compressors. - now for the fun part!
Work the cylinders onto the remaining 2 pistons. Some cursing may be involved...and necessary!
Rejoice when all 4 pistons are inserted past the rings

 

[djorgensen3]

I just started a couple of hours ago on this same type of job for a guy here in Phoenix. I just got the motor removed and will split the cases tomorrow. It seems to go so much easier after you've done it a couple of times before.

 

[loboboy]

I'm working on the same thing, pulled out second gear to get it undercut, and have a question...
how did you reinstall your pistons into the cylinder?? I'm stuck on that part.. it's hard to compress the rings, and get the cylinder head on at the same time... do you have any tips/tricks on getting it back in???

I did not remove the top end, all I did was released the tension on the cam chain and then removed the lower case without removing the cylinder or the cylinder head. it split apart like a freshed cooked turkey on Thanksgiving and now I am waiting on parts to begin the reassembly. I am investigating some other avenues to get my tranny under cut so I don't run this problem again. Will keep everyone up to date as the prgress goes on.

 

[joseph717]

LOBOBOY,
I DIDN'T KNOW THAT YOU CAN JUST REMOVE THE LOWER CASE...
I WAS JUST FOLLOWING THE SERVICE MANUAL.. DAMN..
OH WELL, IT WAS AN EXPERIENCE.
OMSLAW -- THANKS!!!

 

[loboboy]

sorry to burst your bubble, I did alot of research and asking questions before i started because I really didn't want to remove the top end.

Now of course I haven't put it back together and run it yet so I may have done the wrong thing but only time will tell.
One good thing is that I am definitely not as intimidated by tearing into it now though.

 

[Haya01B]

I tore mine down and replaced my whole trans with one I picked up off ebay and sent off to have undercut back in 06'. It took me about 3 and half days because of back and forth trips to the store for different things. The one thing you have to look out for is the Crank shaft balancer. It has to be installed a certain way. You do have to remove it because there is a bolt under it holding the two crank case halves together. I did not have to do anything to the top end. Everything is where you can get to without the need to remove the cylinder head, block or timing. I think it was a good experience and I got to know my busa a lot better. I do want to tell you to make sure those shift forks are in right because they are tricky to get in place when trying to mate the two crank case halves together. You will definitly save big time as opposed to going to the shop to have it worked. My buddy took his to the local shop and had a two month wait during the summer. Good Luck! and if you have a question to ask me I will be more than happy to assist where I can.