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Old 11-25-2013, 09:50 AM   #31
crushing OP
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Quote:
Originally Posted by kamanya View Post
I wrote this for a guy who had to preform the same thing, So please forgive the detail;


Good luck!
Wow! This seems like a complete list. Thanks so much!

Quote:
Originally Posted by Motomedic View Post
Great post Kamanya.

Only real thing I'd add is I'm more in favor of buying the complete gasket kit. That way, you've got everything in one place, and if you need a gasket you didn't plan on, well, there ya go.
I'll order the complete kit for sure. Very good suggestion.

With all this help, I feel quite able to tackle the repairs. Thanks everyone!
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Old 11-25-2013, 06:04 PM   #32
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I'm considering replacing the shift drum to head off any problems that, in my experience with Murphy's Law, are sure to happen when you are far from home.
I wonder what the actual failure rate is on these things?

I noticed that all 3 shift forks and one shift shaft have been superceded to a newer number, as well. At least on my 2004 950, anyway.
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Old 11-25-2013, 07:34 PM   #33
crushing OP
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Quote:
Originally Posted by AdvRonski View Post
I'm considering replacing the shift drum to head off any problems that, in my experience with Murphy's Law, are sure to happen when you are far from home.
I wonder what the actual failure rate is on these things?

I noticed that all 3 shift forks and one shift shaft have been superceded to a newer number, as well. At least on my 2004 950, anyway.
Good thoughts, AdvRonski. Doesn't seem like a bad idea to preemptively replace it (other than the cost/time). I was fortunate that the failure happened near home.

I would like to know the failure rate too. Looks like a few guys have had the failure and one swapped it out before it happened. Maybe we could poll the inmates?

I wasn't planning on swapping out the shift forks unless they were noticeably or measurably deformed. Hmm...more dollars.
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Old 11-25-2013, 10:24 PM   #34
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Quote:
Originally Posted by AdvRonski View Post
I'm considering replacing the shift drum to head off any problems that, in my experience with Murphy's Law, are sure to happen when you are far from home.
I wonder what the actual failure rate is on these things?

I noticed that all 3 shift forks and one shift shaft have been superceded to a newer number, as well. At least on my 2004 950, anyway.
That's a lot of work for a maybe!

Also, if it does happen, you still have a semi-working gearbox, just you'll have lost a gear or there is a difficulty getting into or out of 6th. You can still get home.

If you were to refresh your bikes engine as a project then do it. But in anticipation of it happening is a bit excessive. There must be thousands of 2004's merrily swapping cogs with no ill effect out there.

I think that clutchless changing in higher gears, crash changing and not being firm and positive with the gear selector can contribute to the issue.
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Old 11-26-2013, 07:20 AM   #35
AdvRonski
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Quote:
Originally Posted by kamanya View Post
That's a lot of work for a maybe!

Also, if it does happen, you still have a semi-working gearbox, just you'll have lost a gear or there is a difficulty getting into or out of 6th. You can still get home.

If you were to refresh your bikes engine as a project then do it. But in anticipation of it happening is a bit excessive. There must be thousands of 2004's merrily swapping cogs with no ill effect out there.

I think that clutchless changing in higher gears, crash changing and not being firm and positive with the gear selector can contribute to the issue.
A lot of work, yes. But the winters are long here in Minnesota, and I'm an automotive technician, so it's not a big deal for me.
Just another reason to spend some time in the Man Cave.
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Old 11-27-2013, 01:52 AM   #36
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Quote:
Originally Posted by kamanya View Post
Necessary
Descriptor Part Number Part
Base gaskets; front 1 60030035000 CYLINDER-BASE GASKET FR 0,35MM $28.90
Base gaskets; rear 1 60030135000 CYLINDER-BASE GASKET RR 0,35MM $28.0
Case gasket 1 60030039100 ENGINE CASE GASKET 0,5MM 05 $13.97
Shift fork rollers 3 50334018100 SHIFTING ROLLER 6X8X5,2 $2.40
Generator gasket 1 60030040100 IGNIT.COVER GASK.MATRI.CS0,5MM $23.95
Clutch cover gaskets 1 60030025000 CLUT.COV. GASK. INSIDE KLI.SIL $16.89

To be safe
Shift Drum 1 60034012300 SHIFT ROLLER CPL. 06 $113.88
Shift Drum Bearing 1 625618050 BALL BEARING 61805 C3 $45.87


Suggested

Clutch basket cover gasket 1 60030027000 GASKET RING CLUTCH 2X3,1 VAMAC $15.13
Water pump gasket 1 60035053000 WATER-PUMP GASKET 03 $4.99
Oil pipe O rings 2 770090021 O-RING 9X2 VITON $0.27
Oil pipe O rings 2 770110021 O-RING 11X2 VITON
Gear position sensor seal 1 770275025 O-RING 27,5X2,5 NBR $0.35
Cam Chain 2 60036013000 TOOTH CHAIN 88 LINK 6,35PITCH $85.29





Good luck!
Hi kamanya,


One question rised. When I don`t detach cylinder heads from cylinders (small bolts), can I put them back using only the new base gaskets?

I have scrolled also pyndon`s thread many times to find this, but there is any mentioning about that – also in repair manual.


Regards
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Old 11-27-2013, 03:06 AM   #37
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Quote:
Originally Posted by desmorado View Post
Hi kamanya,


One question rised. When I don`t detach cylinder heads from cylinders (small bolts), can I put them back using only the new base gaskets?

I have scrolled also pyndon`s thread many times to find this, but there is any mentioning about that – also in repair manual.


Regards
Yep, there exactly what you do. The manual suggests that the pistons are left in the barrels too, so as not to damage the rings during re-assembly.
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Old 11-27-2013, 05:14 AM   #38
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Quote:
Originally Posted by kamanya View Post
Yep, there exactly what you do. The manual suggests that the pistons are left in the barrels too, so as not to damage the rings during re-assembly.

Tried it also, when replacing base gasket after "Pyndon Syndrome", an old tabel and a few construction brackets worked great to make an engine stand.

/Johan
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Old 11-27-2013, 06:37 AM   #39
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Thank`s guys! I have made an engine stand – very similar to DirtyADV`s
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Old 12-20-2013, 10:20 AM   #40
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Pulled the engine!

Split the cases! Will still have to remove the clutch basket and crankshaft.
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Old 12-20-2013, 08:55 PM   #41
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You'll have to put the center cases back together to pull the clutch. You don't have to pull the crank.

Can you see the broken part?
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Old 12-21-2013, 04:24 AM   #42
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Originally Posted by Zuber View Post
You'll have to put the center cases back together to pull the clutch. You don't have to pull the crank.

Can you see the broken part?
Pennie between primary gear and clutch basket sprocket to lock things up?

/Johan
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Old 12-21-2013, 09:13 AM   #43
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Change the locking lever to the later version, the part in the centre of your photo..... looks like its failing already?


60034024144LOCKING LEVER CPL.
$10
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Old 12-22-2013, 08:59 AM   #44
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Quote:
Originally Posted by Zuber View Post
You'll have to put the center cases back together to pull the clutch. You don't have to pull the crank.

Can you see the broken part?
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Old 12-22-2013, 08:59 AM   #45
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Quote:
Originally Posted by DirtyADV View Post
Pennie between primary gear and clutch basket sprocket to lock things up?

/Johan
Ended up using an air gun.
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