Tam's New Bike

With billet machined heads and billet powervalves mine shows an idicated 125-7ish.

[TamSV]

It's all coming together (or rather, apart) quite nicely .



I've had to drill out a few bolts - both LH rearset mounting bolts and one on the front powervalve cover. There's another one still to do on the clutch cover, so I can pull the gearbox and check the 2nd gear slipping problems.

Pistons and powervalves all look good. Wheel and chassis bearings are fine (although the latter had rusty gunk instead of grease) and everythings pretty straight. I've sorted out some untidy wiring issues and just need to put it all back together (with new bolts ).

I've got a leak of 2 stroke oil I need to track down but apart from that it still seems OK and it's not owing me much at the moment.

[hindle8907]

hahah step ladders. quality .

[andrewsmith]

Originally Posted by hindle8907

hahah step ladders. quality .

Tam how many rebuilds this way?
Still make me chuckle when a see it

[TamSV]

Nowt wrong with the "ladder lift" .

Anyway, I'm getting all fancy. I've got a proper headstock stand these days so I've retired the old bird table...

[Skip]

Love it - will follow this thread with interest as I would love to do this but have no skill or money

[TamSV]

As I've said, the bike was slipping out of 2nd gear under load so I've pulled the gearbox to check it out. It's a known problem with the RGV - usually caused by excessive wear on the dogs where 2nd and 6th mesh together.

I've never removed a gearbox before and I think this was a good one to start with. It's a cassette style box so no need to remove the engine.

Clutch cover off, remove the 6 bolts and springs then slide the clutch pack out.



Break out the special tool - clutch holder from ebay - so I can get the centre nut off.



Clutch basket out and kickstart mechanism removed, then undo the 6 nuts around the gearbox case.



Quick tap on the sprocket drive from the other side with a rubber mallet (after removing the sprocket and circlips) and the box slides out.



There's a bit more to it than that, but not much. Pretty straightforward.

One gearbox on the bench.



If at this point, if you don't spend some time twiddling the gears and snicking up and down through the box then you're just weird.

After dismantling the gears, and keeping the worlds supply of washers and circlips in the right order, I can start inspecting for excessive wear.

Sometimes it's hard to judge what is too much wear. Sometimes it isn't.

This is "too much".



I need new 2nd and 6th driven gears plus a selector fork which was worn beyond spec. That should be it sorted.

Then it needs to go back in, which will likely be the trickier part.

Good work Tam

Loving the new sig btw.........................not !!!

[andrewsmith]

Thats a bit excessive.
Out of curiousity, is it new OEMs or patterns you've getting hold of?

[TamSV]

Not sure at the moment - mulling it over. In this case, aftermarket gears are better but more expensive. It's not often that the OEM parts are cheaper.