Badgers gearbox Part Two...AAARRRRRGGGGG

[Blimey]

Now this is what this site all is all about, free and great advice from people who know what they are talking about.

Also it makes great reading for the rest of us, and obviously educational

Keep it up boys and good luck Badger

[jam]

That's the usual parts needed to repair the fault, always buy the gear pinion that has damaged dogs, and the one with which it engages, as if you look at the pockets where the dogs engage you will see that they too are starting to round off on the edges, it is this that causes the two gears to try and push apart when a load is applied to them, which in turn causes the damage to the selector fork, as the gear pinion is forced against it.

[badgerKDD]

Got a qoute for replacing all three worn cogs plus one selector fork this morning, £262! Ahem . Did a lot of ringing around and guess what, 94 reg gearboxes are rarer than the proverbial rocking horse stuff! Last call I made tho, chap had one and can get it dispatched tomorrow, for 156 quid, bit his hand off... you betcha! Its still in the engine so will have to inspect it well , before I fit anything but if alls well can just replace both gear assemblies and selector fork without to much excessive part dismantling. I just hope it arrives by Friday as I don't have the kids this weekend so will be free to spend the weekend locked in my workshop! Wish me luck boys ( and girls ), this time next week my Gix may be back on the road! !

[monkey8414]

good good ...will have to meet up sometime when ur back on 2 wheels matey

[badgerKDD]

got the pictures of the damage.....









NICE!
Really hoping new ( secondhand) gearbox arrives tomorrow!

[jam]

Loking at the damage on the slector fork it would appear that 2nd gear has been kicking back, check the engagement dogs on both 2nd and 5th gear pinion on the shaft as these are likely to be worn and causing the gear to kick back when power is applied.

[badgerKDD]

Thats 5th gear dogs in pic 4, 2nd gear doesn't look too bad, but as soon as the replacement gearbox arrives I'll be checking it over and hopefully just dropping both gear assemblies in to place rather than splitting cogs etc.
As I'm sat here on the net it seems that my gearbox hasn't arrived today , I'm leaving a note in case the courier delivers tommorow, as I'm 5 mins up the road I'll race down and grab it before they bugger off and take it back to the depot in Plymouth or Exeter etc.!

[jam]

I've just been offered a complete RF900 motor which has an oil pump gear problem, but your head and oil pump gears would fit straight on. The guy only wants £60 for it, if you're interested let me know.

[TLS-Moose]

I've just been offered a complete RF900 motor which has an oil pump gear problem, but your head and oil pump gears would fit straight on. The guy only wants £60 for it, if you're interested let me know.

Now that sounds like a deal

Even if you loose a bit of money re-selling the new 'box on ebay, you'll still be quids in

[badgerKDD]

Secondhand gearbox has arrived from straightline racing, came on Friday after I'd left for a weekend in Exeter, obviously , but already booked Monday and Tuesday off so first thing tomorrow I'm going in! Checked it out and it looks in good nick, cogs look clean and stress fracture free, and the selector forks look better than mine so keep em crossed boys ( and girls)!

[badgerKDD]

Engine is back together, gears went in nicely and all functioned on the dry run before putting the engine back together! Tomorrow will be re installing the engine in the frame and then test fire up! If all goes to plan really hoping I may be test riding tomorrow arvo. Every thing crossed I'v put it all back together properly !

[TLS-Moose]

I'd still have that RF900 motor off Jam - if only for the block and pistons

[jam]

You'd need to fit the 750 head on the RF bottom end as the gudgeon pins are different, 18mm on the 750 and 19mm on the RF. What did you seal the crankcase halves together with when you reassembled? I hope you didn't use silicone RTV sealant, as it doesn't allow the cases to mate correctly, always use Welseal or Yamabond/Suzukibond etc which is what it is done with at the factory. The silicone is too rubbery and can stop the crankcases sitting together properly.

[monkey8414]

well??????? is all good mr badger ???

[billinom8s]

i am always amazed when reading jams posts, they are full of so much info that it makes my brain spin.

keep it coming jam