Intruders-Alert

Okay. Will investigate further. Lol.

That slotted cover on left side is a bish to get out. Any recommendations? Lol. Tried strewdriver, vice grip and washer (it bent), vice grip and larger thicker square plate.. Won't budge. Lol

Yeah, it was a real bitch the first time I did the valve lash. I managed to find something that was a tight fit in the slot and a pair of vise grips a lot of huffing, puffing, cursing and sweating until it finally moved. It has an O-ring seal that had become annealed. it will come out but it will need a lot of teasing.

[emoji41]

Lol.. Wish i had an impact attachment to fit. Lmao

Still couldn't budge it with plate and vice grips. I'll spray with pb and let sit a day or 2. Hada swap tires on 4Runner.
Whatcha think bout going super dark-side if i can fix it? Lol

keep going --your heading in the right direction but don't use an impact driver on your cover. You will crack it

Take your time to make the right tool first time or it will be fucked.

I would use a length of angle iron and cut it so it fit perfectly in the slot. 2 feet long would be nice.

To be honest with you I would be removing the clutch cover. I could then dismantle the clutch to know for sure the engine and box are seperated to diagnose further. ( its going to be the next step anyway) You would then be able to turn the engine the right way and not against the cam chain tensioners usual direction.

I would also remove the starter ( one more thing out of the way)

I am quitely suspecting a clutch pressure plate failure, You hav'nt been fitting extra strong springs have you?

Was thinking that would be easier than the slot.. Just pull covers. Lol. Have an inside view of things. If it has to be stripped down.. Might as well get to it and see what's going on already. Just purchased it so no idea as to what was done.

Update:

In photo below.. I had taken the gears out to allow starter to operate separately and it spins clockwise. The big gear behind the magnet has some in & out play, also spins freely by hand in clockwise but locks in counter.. Which is direction starter would be spinning it. Spark plugs are out so no pressure there. I should also mention i found a tiny pc of metal that i thought maybe a gear tooth fragment in the cover.. No idea where it came from so far.



In this next photo.. All appears to be fine; visually. I will be removing the clutch springs and basket etc to see if anything changes.

Uht-oh..
Second look from shifter side shows more trouble.
Looks like 2 rollers/spacers laying in there with shrapnel.

Clockwise and counter allows just a little bit less than a quarter turn before it hangs up.. Chains apear to be intact. How hard should i try turning over engine by hand?
Turning engine moves shaft also.. Dunno why when it's supposed to be in neutral.

Clutch basket and gear removed..



Now allowing engine to be turned completely in both directions.
So.. Aside from the loose roller/sleeve spacers and shrapnel; what do you think is the issue here? Lol.
Why is trans preventing engine from turning?
As is.. I believe i could put the starter gears and covers back on and start the bike without clutch gear in place. Lol. But that would do me no good. Lol.

Put clutch basket with plates and springs bolted in.. Locks up engine. Removed bolts and springs and engine turns free.

You gotta fucked up gearbox. Fit a second hand unit or part out the bike.

[emoji41]

Lechy wrote:You gotta fucked up gearbox. Fit a second hand unit or part out the bike.

[emoji41]

By that; you mean engine swap pretty much right? Lol.

Unfortunately yes.The engine and gearbox use the same oil so you can't tell where the shrapnel has managed to migrate to.

[emoji41]

Lechy wrote:Unfortunately yes.The engine and gearbox use the same oil so you can't tell where the shrapnel has managed to migrate to.

[emoji41]

Imagine i were able to collect the broken up pc's at the bottom.. And pulled those 2 tubes out.. I'd imagine they were needed in there.. Lmao!
And that's gotta have something to do with the clutch springs locking the engine up even when bike is saying it's in neutral right? Lol.
Maybe i'll chop the frame and slam a 1400 in it. Lol.
Freakin crap. Lol
Either that or sell off the tank and tins to pay for a good used engine and bobberize it somethin like i did this vs1400...








Ugh.. Probably just part it and call it done. Will ponder it.

Try removing the final drive bevel gear.

Those pieces don't look like rollers from a bearing.

Is the sprag still intact? it should only turn one way. Thats the intermediary gear between starter and flywheel rotor.

Im think the bits may be locking the tranny and not the tranny locked up.

This all may fizzle out but dont we all want to know what failed, I do.

Also try the gears in each position and note any change in the lock up. (It maybe in 2 gears)

The sprag gear is not the intermediary, it is the big gear behind the rotor, In the pic it looks like the intermediary or dog gear is missing or maybe it fell off when Bronx pulled the cover.
[emoji41]

Yeah well Im not familiar with the 800 you see. In that case he needs to see if that large gear wheel behind the rotor is wobbling and or can turn. Sprags can bust especially when an engine back fires as you crank it. The CDi unit is supposed to retard ignition at start up to avoid it.

Of course it may not be this yet.


Without a full and final diagnosis it could still be repairable if we knew what broke and will it replace.

According to Bronx the sprag is working correctly, the 800's don't have the anti reverse rotation feature like the 1400's do.
The engine turns freely whilst disconnected from the clutch but locks up when the clutch is replaced indicating a spanner in the gears. The 2 pins lurking inside the gear well would indicate something inside exploded or disintegrated.
I would hazard a guess that the previous owner was a boy racer and carried out numerous red light grand prix's upshifting without using the clutch.

[emoji41]