Tranny Failure

[GGRider01]

You've come this far, might as well get a replate. Have you split the cases yet?

[twowheels]

Originally Posted by Jacob 'Berg

The vertical striations are what concern me. They fill rough when I run my finger nail over them. I do not see any flaking, peeling, or pinholes. I could probably throw the new piston and rings and run it without issue....but I would rather be safe than sorry.

Scotchbrite and cleaner and then see what they feel like. If you end up replating send a new piston along and you get a perfectly matched set.

[Zman]

The plating looks different around the port area. I recently saw a similar change in color on a 2003 300 where the plating wore through and it was down to the aluminum base metal. US Chrome does a good Job for replates.
http://www.usnicom.com/

If you are looking for more power you can have Ryan Callies port it before the replate. http://finishlineengines.com/ Ryan also works at US Chrome.

[Jacob 'Berg]

Primary and secondary gear #6 both toast. The secondary gear blew apart. Secondary shaft, one of the shift forks, and shifter fork shaft also knackered. Not sure how this happened, any insight?

[Jacob 'Berg]

My plan is to pick up a complete bottom end from a 2004 and swap the transmission into the 2011. At least then I will have some spare cases and crank for the 2011 or the 2005.

The only part # that does not match up is the secondary shaft. Any clue if this will work OK, or should I shell out the additional cash for a new 2011
shaft?

[Jacob 'Berg]

Anything else I should replace while I have her opened up?

Crank is tight. Needs a new crank seal, as there was some dirt inside the seal.

[twowheels]

While you're there you might as well put crank bearings in. Check the trans bearings too, and clean them very carefully if you decide you're going to keep them. Add a shift fork or two to your list and check the math.

I wouldn't trust the parts fiche () - give Mark a call to make sure you're getting the right pieces, part numbers be damned.

[gasmonkey]

Looks very familiar.Do a search for my thread ' ec250 implosion 'back in 2010.Was repaired with new bits and has been ok since.Hasn't had much use thou.
Once you get ya head around how everything works,it's not all that complicated really.

[Zman]

With all that metal running around in the trans I would change the trans bearings too. You can get most or all of them from the local bearing shop or industrial supply store. These numbers may help you but you should check them against what is in your engine. The two numbers on the right are grainger numbers.
Counter shaft bearing 6305C3 4ZXJ1
Countershaft Seal 30x40x7
Clutch bearing 6205Zc3E
Trans shafts 6203c3 4zxe8

[booth]

I just put my bike together and ran it yesterday.

Motor everything ran great, about 2 hours into the ride while climbing a massive dune, hit at 3/4 throttle wide open in 5th gear, half way up while changing to 4th, motor started laboring and bike slowed down.

Get down the hill and would not cycle through the gears smoothly.

Ride a bit further and engagement became smooth, but engaging 5th and 6th gear there is a "clicking" sound that happens, think I might also have transmission damage.....