2003/1600 Engine Disassemble

[Sharpman66]

Hello all! I hope everyone had an enjoyable Christmas and New Years. Here in Canada we hibernate in our homes and are unable to ride until April/May. Unfortunately, last summer i lost 5th gear on a trip through Northern Ontario. It failed at the 200km point into a 1000km trip. She got me 800km home in 4th gear. I strained the oil and nothing come out. Now its time to repair it. I'm using a Clymer service manual and its going well. Step by step instructions and very detailed. Once i get into the transmission and find out whats broken, i'm rebuilding with new rings, gaskets and a Barnett clutch. I noticed the cylinder walls have some scoring and plan on sending them out for a hone. I also noticed a considerable amount of carbon build up on top of the pistons. Does anybody have some suggestions that i should be replacing or inspecting? Cheers!

[Shores]

Do not hone the cylinders! They are coated with a ceramic type material that is bulletproof and contributes to the longevity of the engine. Make sure you have the upgraded oil pump gear.

[Tropicalrs]

The 2003 does not need the oil gear changed. It was fixed earlier.

[Father Pobasturd]

If the cylinder walls really look bad, you have 2 choices: Replace the cylinders or go with a big bore kit. Patrick Racing is the source.There's a set of stock 1700 cylinders and pistons on Ebay for $199.99. IDK if the swap is possible but others may. Good luck.

[Pauli466]

Can you show a picture of that scoring, I've never seen it happen on a 4 stroke with ceramic composite coated cylinders. 2 strokes yes but never a 4 stroke, my 650 had 70,000 miles and i could still see some factory honing marks in the cylinders when i replaced 5th gear. I had the 30,000 roadstar apart last year and those cylinders looked brand new, if the ceramic got scored i can only imagine what the piston skirts look like

[Pauli466]

I used nylon bottle brushes and solvents to remove carbon from the pistons and combustion chambers on mine, there was so much of it the engine had some spark knock and when trying to start it hot it sounded like the timing was too far advanced, after cleaning it up it never did that again, there was so much carbon i couldn't see the valve relief in the pistons on mine

[Lug Nut]

Don't Hone cylinders.... Clean with rag and brake cleaner

If using Barnett pressure plate makensure to use only OEM Yamaha clutch disc's and steels (not Barnett clutch disc's and steels)... Also good idea to get rid of the wire and half clutch disc behind it and replace will a full size one.

Can carefully scrape carbon deposits (get big hunksnoff
Loosing 5th gear is very unusual.... What all happened? What oil has been used? What mileage on bike? How long have you owned bike?

[roadiemort]

Sounds more like slipping real bad in 5th?

[Sharpman66]

Can you show a picture of that scoring, I've never seen it happen on a 4 stroke with ceramic composite coated cylinders. 2 strokes yes but never a 4 stroke, my 650 had 70,000 miles and i could still see some factory honing marks in the cylinders when i replaced 5th gear. I had the 30,000 roadstar apart last year and those cylinders looked brand new, if the ceramic got scored i can only imagine what the piston skirts look like

I found out its not scoring. Just up and down marks. Can't feel it with a finger nail.

[Sharpman66]

I'm here now and there is definitely a problem in the transmission. Shifting through the gears at this point and still no 5th gear. Lets get this case open.

[Sharpman66]

Don't Hone cylinders.... Clean with rag and cleaner

If using Barnett pressure plate makensure to use only OEM Yamaha clutch disc's and steels (not Barnett clutch disc's and steels)... Also good idea to get rid of the wire and half clutch disc behind it and replace will a full size one.

Can carefully scrape carbon deposits (get big hunksnoff
Loosing 5th gear is very unusual.... What all happened? What oil has been used? What mileage on bike? How long have you owned bike?

Thank you for the clutch and cylinder info. From what i've read there was an issue with the 2003 R* 5th gear other than the circlip recall. I was riding along and shifted from 4th to 5th and the shift didn't feel right. it felt like a soft "crunch" so i let the clutch out and nothing there. It reved up like i was in neutral. Pulled over and stopped. Started off again shifting through the gears perfectly, until i shifted into 5th and again nothing there. I've always used Yamalube 10W-40 and never had a problem. The bike has 67,000 km (42,000 miles). I've owned the bike for 3 years. I'm not sure how the previous owner rode, but i do know he did ride 2 up. I usually ride 2 up with luggage and have to admit i've lugged it a few times in 5th. An 18 year old bike i think she needs some attention.

[Sharpman66]

Do not hone the cylinders! They are coated with a ceramic type material that is bulletproof and contributes to the longevity of the engine. Make sure you have the upgraded oil pump gear.

I had no idea they are coated! Thank you!

[Sharpman66]

Just a little update...I've got the case open and found this. Dogs broken off 2nd/3rd Pinion.

[Duke]

Make sure you don't lug the engine in any gear. If your getting chatter when twisting the throttle, you would be in "to high of a gear".

[Tropicalrs]

Looks like something had to give. And that is the result!

[Pauli466]

I found out its not scoring. Just up and down marks. Can't feel it with a finger nail.

That's the crosshatch honing, those cylinders are like new, don't remove the carbon ring from the side of the piston, that carbon ring helps control oil burning