Duckndive Posted October 5, 2022 Share Posted October 5, 2022 For what its worth a new 2nd gear is £63...and a new 5th is £96 ish https://www.suzukiparts.co.uk/shop/online-store/suzuki-parts-finder/gsx-r/gsx-r1100/k-l-1989-1990.htm?vehicle_id=49#!gsxr1100kltrans Quote Link to comment
Jdeac Posted October 5, 2022 Author Share Posted October 5, 2022 I remembered I e got an old b12 box. Third is toast 2 Quote Link to comment
Jdeac Posted October 5, 2022 Author Share Posted October 5, 2022 1 done. Stripped cleaned. Best of each. Oil at the same time as assembly 2 Quote Link to comment
Jdeac Posted October 5, 2022 Author Share Posted October 5, 2022 Decided to leave the clutch shaft as they are both in pretty much the same condition. Loads better. So fingers crossed. I guess I can out the lower case on and cycle the gears?? Quote Link to comment
Jdeac Posted October 5, 2022 Author Share Posted October 5, 2022 So I've popped the lower case back on. Cycle gears and it's hanging between shifts. On the end of the drum. If I rock through sprocket forward and back it clicks on the forks of the selector shaft. Am I missing something?? Quote Link to comment
Jdeac Posted October 6, 2022 Author Share Posted October 6, 2022 Got all excited putting it all back together. But ta da. Gears cycle nicely now its all torqued up. Sorry for no pics Need to sort some beer tokens and contact @Gsxrsamfor a new lockup back plate. Speak soon. The old one is buggered Need a couple of gaskets and get the clutch in. But all in all I'm quite happy with myself for doing it. I'll be on the look out for a good bandit gearbox to have properly worked for strength etc. But a big thanks to @davecaraon the end of the phone so to speak. Very patient you are lol. And to all above for all input. Proof is in the testing so when it's all back together in the bike. I'll be off testing my work. Fingers crossed. And thanks again all OSS ALL THE WAY 2 Quote Link to comment
inmate Posted October 6, 2022 Share Posted October 6, 2022 @Jdeacdid you use sealant between the two cases, if so what did you use? Quote Link to comment
Jdeac Posted October 6, 2022 Author Share Posted October 6, 2022 @inmateyes I did. Three bond 1215. Sell it in riders if you have one local. In black and grey. Very thin spear. Was advised to go real carefull around the shells. Also note the dowels on the output shaft and clutch shaft. In the 2 big bearing. Follow the sequence for bolting down the lower case around the crank. The 12mm head bolts and the 2 6mm Allen's by the oil filter. It's in the book as 6mm and 8mm but this is the shank diamiter. Wish I hadn't got carried away and done more pics. 2 Quote Link to comment
Jdeac Posted October 6, 2022 Author Share Posted October 6, 2022 I found it handy to put all bolts into some empty cases. If you have any. Then when I was finished I checked the empty cases split. Showing I had everything back in order. Then double checked torque on bolts/ 2 allens and the 2 small nuts. Not done this before. And taking time and keeping things clean was a big help. Again this was advice from members above 2 Quote Link to comment
inmate Posted October 6, 2022 Share Posted October 6, 2022 @Jdeacthanks for the info, it all helps. 1 Quote Link to comment
Jdeac Posted October 6, 2022 Author Share Posted October 6, 2022 @inmateAlso on reassembly make sure box in in neutral and shift drum also. It's in the manual. But I missed this on my first dry assembly. So much easier 1 Quote Link to comment
Jdeac Posted October 6, 2022 Author Share Posted October 6, 2022 (edited) @inmateLoads of members were a big help. I asked loads of questions privately. If you get stuck ask. Really enjoyed doing it . just hope in works. Everyday is an OSS skool day lol Edited October 6, 2022 by Jdeac 2 Quote Link to comment
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