Another transmission issue? - Wrist Twisters
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post #1 of 92 Old 07-08-2012, 11:09 AM Thread Starter
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Another transmission issue?

I have an 02 919. Recently I decided to tighten the chain. Then it started making and chunky noise coming from around the front sprocket. I loosened it back up no change. I took it on a ride today and its getting worse. It happens when I am coming to a stop. Wether its in gear or in neutral. Brakes or no brakes. It's making several popping/ clunking noises. Sounds like its coming from the tranny. It shifts through all gears great.Runs great but sounds like something is about to break when rolling to a stop. I put it on the stand and in gear still doing it. Took the front sprocket off. Put it in gear. Still sounds bad. Bad clutch? Tranny? Could it just be the chain adjustment?

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post #2 of 92 Old 07-08-2012, 11:40 AM
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Chain aligned?

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post #3 of 92 Old 07-08-2012, 11:47 AM Thread Starter
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I am using the notches on the swingarm.

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post #4 of 92 Old 07-08-2012, 11:57 AM
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Quote:
Originally Posted by redline919 View Post
I am using the notches on the swingarm.
Yeah those aren't really accurate according to most on here. But I wouldn't think it would be that far out to cause a clunking sound.

Hopefully you didn't run it so tight it messed up the spline going into the tranny. Apparently it can mess up the countershaft seal.How much slack do you have? I run mine at about 1.5 inches, when I ran it tighter I did get a clicking sounds, but it was fixed by loosening the chain.

If it shifts fine I wouldn't think the tranny is messed up. I bet it's related to the chain (tension/alignment/lubrication)

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post #5 of 92 Old 07-08-2012, 12:05 PM Thread Starter
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Let me loosen it some more real quick and c if that helps. Honestly I tightened it until the chain hit the rubber guard on the swingarm which was about an inch. I checked it just after i adjusted and rode it it was about 1 3/16 so its maybe still too tight. I am kinda unsure where to measure from. Is it dead center between the sprockets where I check the slack?

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post #6 of 92 Old 07-08-2012, 12:08 PM
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Quote:
Originally Posted by redline919 View Post
Let me loosen it some more real quick and c if that helps. Honestly I tightened it until the chain hit the rubber guard on the swingarm which was about an inch. I checked it just after i adjusted and rode it it was about 1 3/16 so its maybe still too tight. I am kinda unsure where to measure from. Is it dead center between the sprockets where I check the slack?
Check it with the bike on the side stand, and it should just hit, or come very close to, the end of the rubber swing arm pad. That's where I keep mine and that is about 1.5 inches of slack. It doesn't sound like it's too tight.

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post #7 of 92 Old 07-08-2012, 12:10 PM Thread Starter
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I was checking more towards the middle of it

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post #8 of 92 Old 07-08-2012, 12:13 PM Thread Starter
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My back sprocket looks pretty worn also that could be part of it

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post #9 of 92 Old 07-08-2012, 12:14 PM
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If it's hitting that pad in the middle of it I don't think it's too tight. When mine made noise it wouldn't hit the pad.

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post #10 of 92 Old 07-08-2012, 12:47 PM
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I have had that exact symptom before and it went away when I loosened the chain a bit.

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post #11 of 92 Old 07-08-2012, 01:14 PM Thread Starter
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So I loosened it a lil and cleaned everything and it seemed to help some until I made the chassis flex by accelerating and then braking hard. I took a ride with no helmet and its seems to coming from the rear sprocket not the front now. The teeth are pretty worn so I'm just gonna pick up a new set. Hopefully that's all it was. Here is a picture. Thank you for your help.

ForumRunner_20120708_161138.png

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post #12 of 92 Old 07-08-2012, 01:17 PM
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Woah, yeah those are done for

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post #13 of 92 Old 07-08-2012, 01:21 PM Thread Starter
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Lol must have been that last trip to St Rt 10 and 22 in Kentucky that did them in.

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post #14 of 92 Old 07-08-2012, 01:23 PM
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Yup, that rear spocket is shot! Most likely the chain is near its last leg too due to the excessive wear placed on the chain from the sprocket teeth. Might be a good idea to just go ahead and replace both sprockets/chain.

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post #15 of 92 Old 07-08-2012, 02:08 PM
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I'd bet as soon as you get a new chain/sprocket set on there the noise is gone. I went with the stock gearing with steel sprockets and DID X-ring and it's great. That DID is expensive but I haven't had to mess with it at all, I just keep it lubed. I was adjusting the stock chain like once a week.

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post #16 of 92 Old 07-08-2012, 02:21 PM Thread Starter
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I will buy a set. It has a 520 16t/43t on it now. I like the gearing of it.

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post #17 of 92 Old 07-08-2012, 02:37 PM Thread Starter
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It has the DID 520VM which is the x ring I believe

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post #18 of 92 Old 07-08-2012, 03:19 PM
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A sticky chain will do this, too, did you lube it?

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post #19 of 92 Old 07-08-2012, 03:23 PM Thread Starter
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Yea I lubed the first time I adjusted. The chain lube was super sticky tho

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post #20 of 92 Old 07-22-2012, 06:22 PM Thread Starter
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So I bought new chain and sprockets. The countershaft sprocket is a vortex 520 pitch 16t. The thing is that it has a little side to side play. The bolt and washer will not clamp down on the sprocket. Is this ok? It's not much play but enough to make me question it.

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post #21 of 92 Old 07-22-2012, 07:42 PM
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Quote:
Originally Posted by redline919 View Post
So I bought new chain and sprockets. The countershaft sprocket is a vortex 520 pitch 16t. The thing is that it has a little side to side play. The bolt and washer will not clamp down on the sprocket. Is this ok? It's not much play but enough to make me question it.
Most of the aftermarket sprockets are like that. Mine last two have had a little float...no issues and I figure it's self aligning

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post #22 of 92 Old 07-22-2012, 08:08 PM Thread Starter
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Just wondering if I should put a washer on it. Very hard to find that size

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post #23 of 92 Old 07-22-2012, 08:26 PM
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Ok that's just awesome.. scrolling through current threads and I see -another transmission problem- .. I think man I thought this bike was bulletproof.
I start reading and, its just a bad sprocket. that's what up..
:919:

Ok cya

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post #24 of 92 Old 07-23-2012, 03:12 PM Thread Starter
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Well my problem still exists. Brand new chain and sprockets. Oil change. Adjusted the chain correctly. Aligned the wheels. Still have the noises. Seems like it mostly in 1st while taking off and stopping. It feels like it coming from the front sprocket but sounds like the rear sprocket is clicking. I don't know what to do at this point. Last 2 things it could be is the transmission or rear wheel bearing. Any ideas? I'm seriously getting ready to part it out. I've never had a bike give me this many problems. It only has 15k miles on it

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post #25 of 92 Old 07-23-2012, 03:15 PM
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Quote:
Originally Posted by redline919 View Post
Well my problem still exists. Brand new chain and sprockets. Oil change. Adjusted the chain correctly. Aligned the wheels. Still have the noises. Seems like it mostly in 1st while taking off and stopping. It feels like it coming from the front sprocket but sounds like the rear sprocket is clicking. I don't know what to do at this point. Last 2 things it could be is the transmission or rear wheel bearing. Any ideas? I'm seriously getting ready to part it out. I've never had a bike give me this many problems. It only has 15k miles on it
Take pics of your chain slack? My chain would make a 'clunky' sound at slow speed, especially when using the back brake. This was due to not enough slack and a dry chain.

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post #26 of 92 Old 07-23-2012, 03:24 PM Thread Starter
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I have checked it 20 times. It can't be that hard to adjust chain slack. There is something else wrong. I set it to spec. Loosened it a lil. It doesn't matter where the chain is adjusted to it still does it

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post #27 of 92 Old 07-23-2012, 03:35 PM
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Were all the splines in good condition when you replaced the front sprocket?

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post #28 of 92 Old 07-23-2012, 03:39 PM Thread Starter
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Yes

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post #29 of 92 Old 07-23-2012, 03:40 PM
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I wonder, can you get the back end up with a rearstand? Then throw it (carefully) into gear? Does it make the same sound when suspension is fully out and not under load?

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post #30 of 92 Old 07-23-2012, 03:51 PM Thread Starter
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I did that when its not under load it sounds worse. I slowly released the clutch and let the wheel spin. Every so often it wants to jump around sounds like its something in the transmission. But under a load on the street sounds like a popping crunchy sound from the back wheel. I'm lost

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post #31 of 92 Old 07-23-2012, 04:16 PM
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Quote:
Originally Posted by redline919 View Post
I did that when its not under load it sounds worse. I slowly released the clutch and let the wheel spin. Every so often it wants to jump around sounds like its something in the transmission. But under a load on the street sounds like a popping crunchy sound from the back wheel. I'm lost
Before you throw out all hope, have you considered taking it into a dealer/shop?

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post #32 of 92 Old 07-23-2012, 04:18 PM Thread Starter
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I think I messed up the countershaft or rear wheel bearing. I may have overtightened the chain which is when the noises started. I didn't ride it long like that tho. I put the new chain and sprockets on. I used string line to align the wheels and a ruler to measure the chain slack vertically. The chain is almost touching the back end of the rubber swingarm pad when slightly pushing up on it while on side stand. I also went by the adjustment plates the first time I adjusted it when noises started. The string line shows the plates be 1/8 off which was way out from front to rear

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post #33 of 92 Old 07-23-2012, 04:22 PM Thread Starter
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Yea but I have been working on bikes for years and can usually fix about anything. The stealership is gonna rape me and tell me I need a new transmission even tho it shifts fine

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post #34 of 92 Old 07-23-2012, 04:24 PM
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My bet is on your rear wheel and/or cush drive bearing then.

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post #35 of 92 Old 07-23-2012, 04:27 PM Thread Starter
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Hmmmm.... Let me go inspect. That would be awesome. Thanks for the help

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post #36 of 92 Old 07-23-2012, 05:16 PM Thread Starter
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The bearings seem ok. They move freely and smooth. I even put the wheel and axle on jackstands and spun the wheel. Sounds like I have a tiny rock or something in my tire. Definitely not the problem. I am really thinking the countershaft itself or its bearings are bad. The only other thing I saw was the upper chain guide toward the back was not pushed down into the hole in the swingarm. Maybe it was throwing my chain adjustment off or the chain links are grabbing it. I doubt it tho

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post #37 of 92 Old 07-23-2012, 07:09 PM
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post #38 of 92 Old 07-24-2012, 03:52 PM
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Right before my right side wheel bearing went out I thought my chain needed tightend. Same noises you speak of and could FEEL it in my left foot. So I tightend the chain, the next day on the way home the bearing shit its pigs the only balls left were inside the hub of my wheel. Had to call a buddy to pick me up with his truck. Then had to use a dremel to cut through the race and a small chisel to get it out. Replace them before they go completely out will be way easier on you. I got a complete set with seals from boss bearings through ebay for like $26 shipped.

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post #39 of 92 Old 07-24-2012, 04:24 PM
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Did you check the cush drive bearing? Not the two wheel bearings, but the larger bearing?

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post #40 of 92 Old 07-24-2012, 05:16 PM Thread Starter
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Yea I checked it but I can only check by feeling it and looking at it. I really feels like I have countershaft issues. It almost feels like when I stop the bike in gear pulling the clutch lever the countershaft rolls a couple inches more after the bike is stopped. Seems like the front and rear sprockets are fighting each other or something.

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