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Discussion Starter · #1 ·
Well I finally got all my parts together to replace my can chain. I pulled the trans cover to clean the oil strainer. When I was about to put the cover back on I noticed something odd looking inside the transmission section. It looked like a cracked gear. When I finally got it to move I realized it was a piece of metal but it was all chewed up like it had hit the gears. As I was trying to get it out it fell down to a spot that I cant see or get to. Before I messed with it it was in a spot that wouldn't touch anything while the engine moved but im sure it could have been dislodged with a bump or something.



Now for my questions. What do I use to get the clutch basket off? What the hell could this thing be? Do you think it is even worth my time or should I start the search for a replacement engine?
 

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Was it a steel part, or brass?
 

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May have to turn the engine upside down and blast that chunk out using carb cleaner with an extension tube if a magnet won't get it. I would retrieve that part, take a pic and see if any of us can identify it.
 

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Discussion Starter · #5 ·
It looked steel not brass. My goal was to pull the clutch basket off then whatever is behind that so I can access it. I will try shaking it around a bit upside down to see if I can dislodge it. When I drained my oil I did notice a slight amount of metal shavings. All appeared to be silver in color and not to large. The cam chain had worn into the casing so I thought that was what had caused it.
 

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Clutch basket removal. I used what is called The King Gator Grip. It is a socket with a bunch of pins with springs inside. The pins that touch something push in, the ones that don't stay out. Designed for stripped bolts or to grab just about any bolt head. It works great on that odd shaped nut for the clutch basket. About $20.00. Some people have made their own tool cutting up a socket.
 

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Dang, so do I, never figured out where it went to, and never think about it when it might be handy. Thanks for the reminder, Nate! The search is on....
 

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It looked steel not brass. My goal was to pull the clutch basket off then whatever is behind that so I can access it. I will try shaking it around a bit upside down to see if I can dislodge it. When I drained my oil I did notice a slight amount of metal shavings. All appeared to be silver in color and not to large. The cam chain had worn into the casing so I thought that was what had caused it.


Was the engine running before?

Was it knocking?

If any metal got under the big-end shells the crank may be ruined.If you caught it in time you will need to power wash/flush the engine totally and compressed air blow out.The only other way to be sure is to strip to the crank and check the shells/big-end bearings.
 

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Discussion Starter · #11 ·
The engine was running before. It had what everyone thought was cam chain noise. It was a larger piece of metal. Hard to imagine what it could be.
 

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Discussion Starter · #12 ·
I guess another question is can I gain access to the area right under the transmission by taking the clutch basket off? Is there a cover plate or something that can be removed after the basket?
 

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I have a clutch nut removal tool now, but in a pinch

have used a drift/blunt chisel to knock the nut off.

If its big enough I doubt that rogue peice of metal has

gone into the gearbox as the case is closed behind the clutch



You really need to get it out and have a look at it though

knowing what it is may help decide how serious an issue it is.

Any smallish debris can move between the front and rear of the engine case

via the hole behind the oil pump, so knowing what it is will help tell where it came from



Show us a pic of it too !!
 

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That sounds dangerous, any clue how long it was making noise? Also you gotta figure out what caused the cam chain to knock the chunk off, if that is what it was... If I were you, I'd do a full engine rebuild to be safe, otherwise you could have it blow at any time depending on what it is and where it's from, how long the metals been around, even small metal shavings in the crank are HORRIBLE for the engine...
 

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I would look for a running cheap engine if possible and then investigate and repair the old one if possible.This is what I have done over the years.I even have a crank shaft in my present CX500 from a US Ebay breakers which I had checked at my local engine/engineering specialist and polished along with the Con rods and pistons and then fitted new shells.

I had the rods checked as visual inspection cannot tell if there is damage to rods even if they look good.BTSTGTTS.
 

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It still boils down to figuring out where that piece came from. If it was due to a stress fracture another piece could come loose at any time and you may not get so lucky.
 

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Discussion Starter · #17 ·
Yeah the goal is to find the piece. Post up a picture and try to figure out what it is and where it came from. I know the piece is in the gear box because I saw it there and tried to pull it out but it just feel further.
 

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Discussion Starter · #19 ·
Okay good news and bad news.



Good news I found what was in my engine. Pictures to prove it.



Bad news the transmission fell apart when I pulled the cover off. Now I feel a bit lost.





Anyways heres some pictures. Ideas? I found two pieces. The round bar I believe came from parts of the transmission but what in the heck is the metal bit? It is about 3/8 of an inch wide at the flat spot if you can see it.



















 

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The metal piece could be a dowel like in the rear of the engine case that helps it locate when fitting.There are usually two.



As for the gearbox they are not easy to reconstruct if you have let any of the gears and thrust washers come away without taking note of where they go.



I can re-build them but only,"Hands On" as it's just too messy to try and explain.You need to get someone with good mechanical knowledge down and really look at the exploded manual diagrams together with you as they are very confusing the 1st couple of times and everything has to be in exact place including thrust washers.



Whilst you have got this far I would get the crank and rods out,carefully and check the big end shells.It's not easy getting the crank shaft end cap off without damaging it.Again you could do with some experienced help around or take the Crank case to known engine builder/mate.
 
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