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Found 12 results

  1. Hi, so after a countershaft bearing failure I needed to take the engine apart for inspection and repair. I had a few questions that I think the forum members will be more knowledgeable than me. 1) I have pitting in my 2ND DRIVE and 4TH DRIVE gears and I am unsure where the damage could come from(Without affecting the DRIVEN gears as those are fine) and if I should replace the gears. 2) I will be replacing the oil pump completely as that is worn a lot from metal shavings, but the problem is that one side of the pump goes against the case and there are score marks in the aluminium. They aren't gouges, but you can feel them when dragging with your nail. Getting a new case isn't really a good option. Is there a possible partial fix I can do to lessen the damage or should I not worry about it too much? 3) The splines on my countershaft sprocket are a little worn with noticeable play with the sprocket on. Red loctite fix hasn't really been helping and the sprocket nut still comes loose after a while(Maybe 1000km or something). I included a video where you can both see the play and the wear on the splines. Should I just not worry about it and keep tightening the nut every once in a while? Or is there some fix other than ~100Eur shaft replacement? Youtube link to the sprocket video Thank you, very much for any help you give me for these questions.
  2. Hi everyone, I have been having a problem with my CRF70F for a little while and after trying to make adjustments to fix it with no results I thought I would ask around. Also I have not found any answers online about this problem, one person claimed to have had the same problem but never got an answer and the question was almost 7 years old on the site. My problem is that my bike will continue making a "click" ing sound continuously while at all times when at idle and while driving. At idle, the sound is very slight and sometimes not noticeable, but when the bike is put into gear it does get louder and faster. Along with the sound, it also causes the bike to receive the power from the engine in "jumps" where something seems to be skipping inside the engine. If anybody has ever had this problem or has any idea what it could be any help would be very greatly appreciated. Thank-you
  3. Alright, I've done quite a bit of research without finding anything, hoping some other BRP owners/mechanics can help me out. I've only had my XR600R for a few months, but it hadn't let me down or leaked any oil before. Until out on a ride, downshifted around a turn, and heard some expensive noises. Looked down to see a bunch of oil flung out all around the front sprocket. Before the ride, I'd added 1/3 quart of oil and later realized it was overfilled, so maybe some internal seals blew out via my own dumb fault. Back home on the stand, I cleaned everything and noticed a fresh nick out of the stator case right in front of the front sprocket. I'm think when I downshifted there was some slap and the chain came off of the front sprocket, which was the grinding noise I heard. But how could a chain coming off be related to an oil leak? With the front sprocket off, I could shift through every gear and back down without a drop of oil coming out. I cleaned the whole drivetrain, put the sprocket and chain back on, did the same thing, and oil flung out and turned my chain black again. So it's only leaking under load? I replaced the countershaft seal, very carefully, plenty of grease, tapped it in with a big socket, and the problem is still exactly the same. Also, the countershaft itself is rock solid. And I got a good view of the bearings with the countershaft seal out and they looked fine. I'm not sure why it's only leaking under load. My dad noted it could be a pressure problem, maybe the crankcase not properly ventilated. Please share your opinions, thanks in advance for your time and help!
  4. Anyone have a feel for where Suzuki is at on there late model DRs as far as the known factory flaws (loctite fixes)? Picked up a 19 with 500 miles on it but I’ve never had one so new. I’ve heard mumblings that some of the issues were resolved in the late 2000’s but I’m not sure if that was true or if it was just lazy people who didn’t want to take the time to make it right trying to feel better about the reliability of there bike. Any help or advice would be great. The bike is a clean slate and I’m ready to get my hands dirty.
  5. I was about to replace my sprockets and chain, when I noticed that the countershaft seal screw is sheered off and the threading is broken. I am having a difficult time trying to find what exactly I would need to order to fix this, or if I want to just take it to a garage and have a professional do it. I am just confusing myself more than anything, so I figured I'd ask questions rather than continue to be frustrated. Please ignore the fact the sprocket looks like hell, I know this. The chain snapped while riding and sheered a bunch of things in a fantastic way. 😐
  6. Hi guys. First post here after lurking for a while 🙄 My front sprocket is leaking. I've read all about the locktite fix. I have yet not done anything. I don't have a 30mm top (arrives tomorrow), so I haven't been able to verify if the sprocket bolt can be tightened. But it is not "finger loose" at least. I am ordering new seal, o-ring, spacer and screws. Now to the question: I have some off-road training coming up tomorrow and a 200km gravel trip on Sunday. Parts won't arrive before next week. If I verify that the bolt holding the sprocket is not loose - and hence the leak must be due to seal/o-ring failure - how slow/fast will it usually develop from here? Right now it is a few drops after turning off a warm engine. Think it will only worsen slowly or can it suddenly start pissing oil all-over? Thanks in advance, Denmark
  7. My son's friend was riding his '05 230 in second gear when a stick jammed into his rear sprocket and stopped the bike dead - they said "a loud crack/pop came from the motor" when the wheel locked up. They started the bike but the gears wouldn't engage. I looked at it and the counter shaft was sticking out of the engine case more than it should. I can grab the front sprocket and move the counter shaft in and out of the engine case. I've done nothing to it yet - haven't even removed the front sprocket to see how far the counter shaft will pull out. I have a couple questions I hope y'all can help with: First, considering he was only cruising along in second gear, what's the likelihood that the damage will be contained to the transmission? Do y'all think the wheel locking up at that speed could have damaged anything else in the lower or upper engine - or even the engine case itself? Second, how difficult of a fix might this be? I have never messed with a transmission but, on other four-stoke bikes I've replaced clutches and flywheels, rebuilt a top end, replaced wheel and body bearings, rebuilt 250x forks and such things. How do you think this transmission job might rank in difficulty compared to those types jobs? I'm just trying to get an idea if it's something I might can tackle for him - he's pretty sure his dad won't want to pay what it would likely cost for Honda to fix an '05 230. Any advice/help is greatly appreciated.
  8. I know front sprockets should have play to it but is this too much or is this normal?
  9. Hi all, long-time lurker, first-time poster here. I've learned a ton from reading this forum, now I could use some specific help. tldr; I’m a relative newbie, I think my countershaft cracked while I was riding and I lost the nut. Somehow the sprocket didn’t slide off until I parked. Now I need to get it fixed…I don’t think this is something I can do myself. I’d love some guidance on what I need done so I don’t get taken for a ride by the shop. Long Version: It’s a DRZ400SM from 2006, new to me as of a few months ago. The other day I took it out to clean/lubricate the chain, which was overloaded with gunk and dirt. I cleaned it with kerosene and lubricated with one of those overpriced motorcycle chain sprays. I also removed the C/S sprocket cover and cleaned around there before lubricating. Everything looked good, there was no play in the sprocket nut. (I don’t know if the previous owner did the loctite fix, but I’m guessing not.) In the morning I took it out for a ride on the freeway. It performed wonderfully at indicated speeds up to 140km/h. I parked at a rest stop, drank some coffee, tried to walk the bike backwards out of a parking spot and the rear wheel locked up. I looked down and saw way too much slack in the chain. Got off the bike, opened the sprocket cover, and found this: After removing the dangling front sprocket: Spent the next few hours waiting for a tow and reading this forum to try to figure out what’s happened. Seems to me like the countershaft cracked and I lost the threaded part, so the only way to repair this is by replacing the countershaft. And from what I gather, that means removing the engine from the bike and opening up the bottom end. At least that's what I learned from this thread, although I'm not positive I'm facing the same issue: Questions: Is my diagnosis correct that it's a cracked countershaft? Am I correct in thinking I need the countershaft replaced, and that this is a big job that includes removing the engine from the bike and opening it up? Does this mean I need a "bottom-end rebuild"? Or does that term imply more than I really need here? Even if I could get by with less, does it make sense to try to do so? Or should I just bite the bullet and have a mechanic do a full review and possible overhaul of the bottom end once I’m paying for it to be opened anyway? Bear in mind the engine is from 2006 and I’m the eighth owner…who knows what else is worn out and could use replacing? Does all this also imply a top-end rebuild? Or can the bottom end be done on its own, saving time/money? And if it can, is that recommended? I intend to stop by a local shop or two and show them pictures and see what they say, but I'd like some pointers beforehand so I know what to expect. I don't really have the skills or knowledge to verify that they know what they're doing and are being honest, so any pointers like questions I should ask them or red flags to avoid would be a huge help. Bonus round if you’re still reading and want to speculate: How the *** did I make it to the rest area in one piece? It seems to me like incredible luck that the sprocket didn’t come off while riding, which probably would have meant a rear lockup and lowside on the freeway. What causes this to happen? Was it weakened by my cleaning/lubricating the night before? Just coincidence? Would the loctite fix have prevented this? Or was it just the high speed on an already damaged countershaft? Thanks again to all you experts who take the time to share your knowledge with strangers on the internet, really. The internet is an amazing thing, the way communities form and people help each other out. Never ceases to amaze me. 🙂
  10. I have a leaking counter shaft seal and I've run into an issue that I need your suggestions on. In short the spacer will not come off. I've doused it with PB, WD, hammered on it. Won't budge. How can I get this out??? Tempted to drill a hole in the surface and wack it with a chisel. Not sure if I can drill that hard collar. How about putting heat on it? Thinking maybe a finely directed map gas torch could heat the collar with damaging anything. I can't tell if there is plastic on that tranny from the schematics.
  11. Not very happy. Countershaft splines are TOAST. 94 XR650L with 14k miles. Don't know how I didn't catch this with last sprocket change but these things are done for. Engine is in otherwise really good condition so I'm hesitant to tear down engine to put new countershaft in. Was planning on eventually doing the kick start conversion, so I was going to get an XR600R countershaft, but I'd really like to do a full overhaul (new piston, rings, bore over, etc) when I have the engine on the bench. So here's my question: If I take this to a competent welder, how many miles could I expect out of a tack welded on sprocket? Would JB weld/threadlocker red work any better? Can anyone tell me why my splines wore all the way down to a sharp point at only one end? XRR sprocket is on it now, hoping that'll hold up for at least a thousand or two more miles. Not trying to take the easy way out necessarily; this is my daily driver at the moment and I also have a few long distance trips planned.
  12. have a knocking type of noise coming from my bottome end I was able to pin point it with a long screwdriver up to my ear and it is heard the most at the waterpump cover behind the propellor. I remove the side case. And found that the counter balance shaft behind the waterpump shaft has play back and forth and wanted to know if that was normal when I push and pull on it it makes a cluncking noise.? I have took the whole top end apart also looking for somthing that could be chasing the noise anyone have experience with there counter balance shaft clunking while the engine is running??
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