what would you do?? *pics added*

Yankee, you mind sharing what the actual problem is? Seems to me it's just a metal ring and according to the manual should be easy to replace ??

if you do no good across the road there would be plenty of places that can weld up the whole bit and remachine the groove thats what fitters do you just have to find a shop with the right milling machine.

java there looks to be a grove in the engine case that a circlip or simaler fits into and the outside of it has broken out .

yep... "set ring B" in the top left of that pic there... well, go WEST (left as we are looking) of that... out to the case of the motor itself! well now that we are on this little "case ring"... rip it off.... that WAS your motor housing... gone. ripped off. popped out. ka-put.
now.
what can i do? you have anymore cool pics of how to put it back on?! it is so small/thin you can barely see it in that pic, plus, when holding it compared to the "set ring" it is so flimsy.... just not a good design...
yeah Beryl, will do, but i seriously am beginning to doubt it could work that easily....

yep... "set ring B" in the top left of that pic there... well, go WEST (left as we are looking) of that... out to the case of the motor itself! well now that we are on this little "case ring"... rip it off.... that WAS your motor housing... gone. ripped off. popped out. ka-put.
now.

So it's not the "B" groove but something further forward and smaller ? I cannot find it in the manual in great details unfortunately...

I think he's saying its the metal of the b grove itself that came off!

I think he's saying its the metal of the b grove itself that came off!

yes! the outter (closest to clutch assembly) wall that holds that ring is gone, therefore, it doesn't hold the ring or the clutch shaft assembly in place anymore......

I think he's saying its the metal of the b grove itself that came off!

yes! the outter (closest to clutch assembly) wall that holds that ring is gone, therefore, it doesn't hold the ring or the clutch shaft assembly in place anymore......

I get it now... farrk

lol!! (well, it's not really "funny ha ha" but like "funny boo hoo"!!)

anyway, next little update.... i found an engine that has ~8K!!!! and they want $1350 Exchange!! howzat?!! (i'm stoked... well, except one thing...)

I DON'T KNOW IF THE '99 and the '00 ARE COMPATIBLE!!! anyone? the wrecker is checking, but, i'd like 2nd opinions! my manual says '00/'01, so i'm doubting it???

Take it home and see if it fits! Don't see why it wouldn't. The wreckers should let you do it.

Good luck man.

snr

hmm the 00 is a new model and did get a revised engine, but the frame and everything is pretty damn similar so I reckon you might get lucky ( you certainly deserve to)

8k engine hey, that's good deal and everything seems to looks the same even the exhaust fitting. Good luck.

ps. maybe a good chance to paint the frame black ?

jeebuz mate, sounds like your getting a bit excited over nothing there! go down to bunnings and get yourself some good duct tape and some superglue (dont get the cheap shit, dodgy work gives dodgy results). glue it back together using said high quality glue, then use the tape to reinforce it. if youre really paranoid, you could use a couple of zip ties around the case to hold it in even more solid, but i wouldn't think its necessary. $10 and your set, you'll even have plenty of glue and tape leftover for when you strip a couple of threads trying to get the f*#$er back together



best advice you'll hear all day, is to never listen to coconuts

Try this mate, http://www.khi.co.jp/mcycle/distributor/index_e.html if the link dosn't work pm me. Send detailed photo's of the failure on the bike and ask them to explain WHY it failed and if it is a KNOWN problem!
Click on Oceanic and send them mail and try Japan too for good measure!

And if they are prepared to do something about it. You might get an answer back..... and then again you might not hear from them.

snr

anyway, next little update.... i found an engine that has ~8K!!!! and they want $1350 Exchange!! howzat?!! (i'm stoked... well, except one thing...)

I DON'T KNOW IF THE '99 and the '00 ARE COMPATIBLE!!! anyone?

The biggest prob I can see is that the G-model uses remote ignition coils and HT leads while the J-model uses plug-top coils. This means wiring loom differences, not to mention that J coils might not fit down the plug tunnels in the G head and cam cover.

The J-model also uses a different ignition trigger (16 "fingers" on the J, 4 on the G). Bolting the older motor in without swapping the ignition trigger over could send the ECU cuckoo...

Have you priced a set of cases?

Because the J went to linerless cylinders, the cylinder/top crankcase interface might've changed, so G-model cases might not fit.

If you get it repaired Marty be very careful, looking at the pictures you put up there are in my mind 2 possible reasons for the failure.
Either a fault in the original casting (possible) or there has been a very big and sudden side loading placed upon that shaft, if this is the case what caused it? You may have to look deeper into this one. By the way what was the condition of the bearing at that end of the case?
Either way you had to be very unlucky. Let me know if there is any way I can help.

Neil

PS keep your chin up!!!!!!

Last edited by Neilp on Thu Nov 03, 2005 8:04 pm, edited 1 time in total.