| Author | Message | ||
     Starbellied_sneetch |
I have a 2003 XB9X on which the previous owner changed the pulleys/belt to the '04 version. Judging by his other work, he probably did something wrong, but it may have nothing to do with this problem. To make a long story short, my bike started running like crap, so I limped it a mile or so to a gas station, pulled in, and discovered the entire bottom of the bike was covered with oil. I finally got around to looking at it today and discovered the problem - I can move the front pulley back and forth/up and down at least 1/4", and in and out at least 1/8". Obviously, it's not supposed to move at all, and that's where the oil's coming from. I figure the oil got into the electronics and caused the bike to run bad. I'm not worried about that, but about the tranny problem indicated by the loose pulley. So, how screwed am I? Where to start? I know that the bolt holding the pulley on is supposed to be torqued to some huge number. I'm afraid to even try taking that bolt off, considering how much the stud to which it is bolted moves. Any advise appreciated! | ||
| Reepicheep |
You are pretty screwed, unfortunately. To fix that on an XB, you have to split the cases. Splitting the cases isn't rocket science, but it's not something to be done lightly either... I did it on a dirt bike and it went fine, I was thinking it was a lot harder then it really was. But there are certainly a lot of little things you have to be careful not to screw up. If you are exceptionally lucky, the 5th gear drive assembly (that output shaft) is fine, and it's the pully that has stripped splines. But if that was the case, you wouldn't be hemmoraging oil.... so I'm pretty sure it's that shaft. | ||
| Starbellied_sneetch |
I'm not sure that anything has stripped splines. The bike was still rideable (although running like crap) when I stopped. The pulley is attached firmly to the shaft, but the whole thing can be moved up and down and in and out. I'd take a wild guess and say that some bearing/seal has crapped the bed. | ||
| Reepicheep |
There are two in there, a set of needle bearings inside that 5th gear drive assembly, and a big ball bearing on the outside of it. For there to be play, it is probably that big outer one. There is a seal over that big outer one that you can pull off from the outside of the tranny and look at that big outer bearing, but I don't think you can replace the bearing without case splitting. Sorry  | ||
| Starbellied_sneetch |
Yeah, I figured it was something exactly like that. Time to get out the service manual and start reading and disassembling! Luckily I have a new '08 STT arriving tomorrow so I'm not in a big hurry to fix it. No need to remove the seal over the big outer bearing - all the pieces of it were laying inside the pulley cover! I'm still a bit worried that I'll really mess something up attempting to remove the pulley, since there's all that play now. | ||
| Sparky |
We're gonna want to see some pix of that new TT, just to help spread some Good Karma around here. Hopefully the joy of getting a new bike and anticipating a new riding experience especially on a singular purpose machine like the TT will Good luck with the rebuild and, if you know a friend that's done this before, invite him over. Two heads can make the job easier and more fun! | ||
| Starbellied_sneetch |
Well, I took my Muller powerclutch out of the '03 mentioned above and installed it in my new '08 STT. While doing so, I noticed metal shavings and chunks under the clutch adjustment cover of the '03. Not cool! | ||
| New2vtwin |
I just recently had the same thing happen to my 03 XB9R. Did you get yours fixed? If so... how hard was the job, any special tools, est cost?? |
