Well for the past couple months now my bike has been getting rather picky about staying in 3rd gear. It wasn't 'that' bad, but it has been getting progressively worse, so finally had to tear into it and get it all fixed up. Got all the parts I needed to fix it, and had a little time since we're not riding this weekend (going to the GNCC races again this weekend!), so decided it would be a good time to tear it apart

Went pretty quick.... I rode it to work yesterday, rode home (carried all the tools I'd need in a backpack and tankbag), got home a little after 6pm, got started on it about 6:30 or so, and it was out and ready to go by 8:30. Not too bad.... coolant was still steaming when I drained it and motor was still warm when I loaded it into the back of my car, LOL. The little A-frame idea worked like a champ! Hard to see in the pic but the whole bike is actually hanging in the air. I'm not gonna lie though, I really do wish I had a cassette style transmission that didn't require pulling the motor out to do this, lol



Took it into work with me this morning to tear it down. Boy was she dirty outside... the rural roads I ride on around here are so much dirtier than other places I used to live. Had to do some scrubbing on the outside for sure. The valve cover gasket was also leaking a little bit too so that didn't help any (it's original.... got a new one)



Inside though... nice and clean. Oil still nice and clean too for having almost 6k miles on it







Original clutch still hanging in there and looking good (256,138 miles)



Once again..... squeeaaaakkky clean inside, always makes me happy to see. Regular oil changes FTW!





Bottom end looks brand new







And here would be my problem..... gear dogs on 3rd rounded off, and of course 6th too since it meshes with 3rd





And got the shift fork a lil bit too



Got the new gears put in and trans back together.... guess I have my work cut out for me monday when I go back, haha. Then I've gotta do a valve adjustment as well.... fun fun. Should have her back together and running again this next week sometime and back to our usual weekend rides next weekend

 

Damn, that's a lot of miles. Lol

 

Your hanging the poor girl lol

 

Wow good job, have fun putting it back together.

 

That would be something I would pay somebody to do. Wish I had your skills. Good luck!

 

Great job! No wonder the bike last that long, you really know the inside!

 

Something Im sure I can look foward to in the future. Joy.

 

Honda's man... You take care of them they will always be there for you... That's incredible on the millage... Gives me hope for my F4i

 

what did the cyl walls look like? man that's a lot of miles! hope it goes back together as quick and easy as it came apart!

 

Thanks for all the great pics! I pretty much do all my own work too, so I'm sure I'll be referencing 'em for something or another in the future. When I dropped the engine for my ZX6 trans rebuild, it wasn't quite as smooth and took WAAAAYYY longer than 2hrs. the way the frame cradled the engine, it was a matter of supporting engine, removing all the mount bolts, then simultaneously raising and pivoting the engine all while it was still within the frame in order to clear. I like Honda's setup much better!

Dude I gotta say, when bike shopping last fall, you were honestly inspiration for picking up my mint 02 F4i and I'm absolutely in love with it!
I did its first oil change last week. 1 socket/wrench, a filter wrench, and nothing to remove to get to anything. Honda FTW!!