| Author | Message | ||
     Jgcable |
Hello, I have the motor out of my 2003 XB9R and everything off of it including all the bolts that hold the 2 halves of the block together. I have been hitting it with a rubber mallet and its not splitting. Is there something I could be missing? I need to access the tranny. Thanks! | ||
| Ericz |
The sealant that is used between the case halves can behave a bit like glue sometimes. Once you get it to separate the slightest, it will come right apart. Be sure you have all of the case bolts out and use a small scissor jack between the swingarm pivot bolt holes just to start the separation, then pull it apart the rest of the way by hand. Be sure your rear motor mount is removed too! | ||
| Reepicheep |
On dirt bikes it can take quite a bit of force to get the split started... I'm guessing the XB motor is even harder (just because there is more "sticking" area and heavier construction). If the crank bearing inner races are binding, heating up the whole motor might help as well. The bearings will expand faster than the crank. But like I said, my data is all from little dirt bike motors, not any HD engine, so take it with a grain of salt. | ||
| Motohead1125r |
There is a case bolt under the shift fork, did you get that one? Be careful you should not have to pry to get it apart. | ||
| M1combat |
BE careful with prying... especially with a freaking jack. IF you're CERTAIN that ALL bolts are removed then it doesn't matter what you use. But if not... Then it matters a lot  . | ||
| Jgcable |
I know I removed all the bolts. I also removed the snap rings on the clutch side thinking that maybe they were holding it up. The pistons are still on the connecting rods and the lifters are still in the block. I am splitting the motor because of a tranny issue. | ||
| Jgcable |
Got the case split. It just took some wacking with the rubber mallet. Found the transmission problem. It was locked up. One of the shifter forks was jammed inbetween 2 of the gears and partially sheared off. Also, one of the gears has a broken tooth, one of the gears spun and the locking tabs sheared off and the shifter fork shaft is bent. The case has no damage so it looks like I need to replace a few gears and I will replace all the fork shafts and forks. All in all, doesn't look that bad to me. Just need to find a source for parts! | ||
| Buellblastrider |
The parts are still available oem if you want to go completely new. | ||
| Ericz |
I have an extra set of gears. Just let me know which ones you need and I'll let you know how much. New gears are over $100 a piece. I don't, however, have any extra forks or fork shafts. | ||
| Jgcable |
http://www.badweatherbikers.com/cgibin/discus/show .cgi?tpc=32777&post=2155745#POST2155745 Thanks alot bro. I will let you know what gears I need. I know I need at least 2 of them. John G | ||
| Buellblastrider |
Shew 100 a piece. My black bikes rebuild keeps getting ore and more expensive. | ||
| Whitetrashxb |
my 03 xb9r transmission suffered the same fate, bent shifter fork... i had the transmission reworked by reputable shop, and now just need to get a gasket kit to put it all back togehter, i'll be following your progress, good luck | ||
| Jgcable |
What do you mean by reworked? I don't see any type of adjustments that can be made to the XB9R tranny. As long as your case has no damage its just a matter of replacing broken parts and slapping it back together. What exactly did they rework? | ||
| Fast1075 |
The transmission can be modified to make it more reliable, easier to shift, more positive in the shift. A "rebuilt" transmission should have all the parts magnafluxed to check for otherwise invisible cracks, have the gears back cut and re-treated and the assembly properly shimmed. When properly done, it will then be more reliable than a new stock transmission. I don't know who to recommend in Ct., but there is a shop in Clearwater Fl. called R&D Motorsports. Mark and crew do the finest possible work. Their client list is a Who's Who of racers. There is no better place anywhere. Several Badwebbers have used them with excellent results. NOBODY else will touch any of my transmissions. (Message edited by fast1075 on December 08, 2011) | ||
| Jgcable |
I will look into that for sure providing its not something crazy expensive to do. As it stands now I planned on replacing the broken parts, getting a full gasket set, intalling new piston rings and valve stem seals and doing the pulley and belt upgrade because mine is a 2003. The bike only has 10K miles on it and is mint. It also has the full Buell Racekit installed whatever that means. I think its the ECU and the muffler. Bike sounds incredible. | ||
| Whitetrashxb |
exactly what Fast said, and that is the shop i sent mine too.. James | ||
| Jgcable |
Got all the gears out. One has a broken tooth, some have broken parts on them, I need 2 shift forks and the rod they connect to. Probably new shims and lockrings too. Any suggestions on where to get parts? I will need to get the new parts and together with the original parts that appear to be ok I want to send them to the machine shop to get magnafluxed. One of them looks like it might have a hairline crack in it and I want to make sure everything internally is perfect. | ||
| Whitetrashxb |
i picked up another transmission when mine was redone, and used the 'best' parts from both. Since the only real damage initially was a bent shifter fork, i still have almost all the parts left, i can scrounge around maybe in a few days and take some pics of what i have left |
