TRANNY REPLACEMENT Sportbike Resource Center Discuss TRANNY REPLACEMENT in the Motorcycle Discussion forums; BACK AGAIN Anyone know how difficult it is to replace the tranny from a 900RR i have seen the guts and it looks kind of intimidating...

[RUBBERDOWN]

BACK AGAIN
Anyone know how difficult it is to replace the tranny from a 900RR i have seen the guts and it looks kind of intimidating

[Ninjakel]

I'm sure someone soon will offer up a wonderful shop that won't assrape you shortly.


Oh, wait.......

[AK74]

I thought someone posted a reference sheet online for this the other day.

[RUBBERDOWN]

I have not seen it

link?

[AK74]

sorry I'm not searching all the posts for that.

[LeeFL2]

Tranny is integral to the lower portion of the engine block. Got to remove the engine, Remove the cylinder heads and cylinder and then split the case if I'm not mistaken. It is a project for sure but can be done if you really want to do it. Need good tools, a good worksurface so you can lay your parts out and label them. Should do it with a shop manual at hand and follow all the proceedures to a T. If you get stuck, go to the 900rr forum and ask for
help. It will save ya $1500-2000.

Good luck!

[Bubbazenetty]

Ok...not to embarrass anyone. But in order to replace the transmission in a HONDA CBR 900RR (not a ZX9)...one has to remove the engine from the frame after removing all fluids from the engine(The head and pistons/rods etc does NOT have to be removed). Then after removing the carburators and harness...turn the engine over and secure it. Remove the right and left engine covers and remove the clutch assembly completely. Remove the bolts holding the 2 halfs of the lower part of the crankcase (part #1 in the picture below) and pry apart carefully..without damaging the contact surfaces.


Now you'll be able to see the transmission gears (pictured below)...and you can remove and replace any or all of the gears that are required in order to fix your problem.



Note that you'll also see the shift drum and shift forks (seen in the picture below). I'd recommend replacing all shift forks that show any evidence of wear (they are #1,#2,#3).


Hope that gives you a glimpse of what you're up against.

PS. See if you can't locate a 900RR service manual as it will make this service much easier to complete successfully. They are available online somewhere for free or a small fee.

[LeeFL2]

In other words, the tranee is not replaceable since it is an integral part of the engine block. What you end up doing, is removing the drive shaft and output shaft, disassembling them, replacing all the bad components and finally reassembling it.

My bad on the cylinders, they are integral to the upper portion of the block!

That is an expensive repair if you need new cylinders. Whole upper case! They could have made those bolt-ons. Much cheaper and easier to RP. Like this Yamaha WaveRunner engine I rebuilt:

Notice that cylinder 1 failed due to an oil injection line that came loose after three years causing the cylinder to loose lubrification and seizing



Here's the new piston installed.



Here's the cylinder, $137 each. Cheaper than replacing the whole case.

[Tungue]

I can't believe this thread has been up all this time and not a single comment about sex changes or cross dressing! What's happening to this place?

[LeeFL2]

AK is out riding...