B4 Gearbox Teardown - MVAgusta.net
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post #1 of 61 (permalink) Old 02-18-2017, 01:48 PM Thread Starter
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B4 Gearbox Teardown

I changed the oil today and had some pretty concerning results. My oil plug had a pretty significant amount of metal flakes on it. I'm thinking I either have a gear or bearing that's going. I've noticed that the bike has been getting much more difficult to get into neutral and shift between 1st and 2nd when it gets warmed up.

I think I'll start by pulling the clutch then the gearbox. Thoughts?

UPDATE: Root cause of the metal was my cam chain idler gear bearing and shaft. The bearing and shaft is located below the cylinder and mounted in the crankcase. There has been at least two Brutales with this issue, possibly three. This repair required removal of the cam cover, camshafts, cylinder head, cylinder, at least one piston and the front chassis for ease of access.
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post #2 of 61 (permalink) Old 02-18-2017, 02:09 PM
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There was another thread somewhere about metal flakes. The OP finally tore down the engine to find the issue.

Here it is: http://www.mvagusta.net/forum/20-mai...sump-plug.html

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post #3 of 61 (permalink) Old 02-18-2017, 04:33 PM
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Smoker;
I'd do a real good job of bleeding the clutch.......if that doesn't fix it look at the clutch pack
then I'd drop the oil pan and check the idler gear and bearing
If the transmission isn't making noise I doubt that's the problem


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post #4 of 61 (permalink) Old 02-19-2017, 05:38 AM
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Smoker,can you please confirm model and year, current mileage also what oil you running and idea of oil change intervals, I guess there was no sign of anything like this the last change?

Certainly something amiss and worth following Noel's advice for next steps.

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post #5 of 61 (permalink) Old 02-19-2017, 06:00 AM
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Quote:
Originally Posted by silentservice703 View Post
There was another thread somewhere about metal flakes. The OP finally tore down the engine to find the issue.

Here it is: http://www.mvagusta.net/forum/20-mai...sump-plug.html

Mate that was me. Long story short. It was the bearing on the lower cam chain gear. Same amount of metal. And I will bet there will be heaps more metal still trapped in the sump which you will have to drop and clean.

You can pull the clutch and gearbox for piece of mind, but if I was you I would take off the rocker cover and if you have access to an inspection camera (USB camera a few bucks on ebay) stick it down through the top until you can see the gear. Then rock the crank back and forth slightly using normal hex key for engine rotation and you should be able to see the gear twist off its axis because if the bearing is gone there is about 2mm of play between the gear and shaft.
If this is the problem you have to go in from the top. I removed the engine but Eddypro stripped his B4 by just lifting and supporting the front end.

Hope this helps.
Rob
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post #6 of 61 (permalink) Old 02-19-2017, 07:52 AM
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@Smoker: Justin, I have a fiber optic camera I can send your way. You actually might have access to one in the "shop" of yours......

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post #7 of 61 (permalink) Old 02-19-2017, 10:21 AM Thread Starter
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Quote:
Originally Posted by silentservice703 View Post
There was another thread somewhere about metal flakes. The OP finally tore down the engine to find the issue.

Here it is: http://www.mvagusta.net/forum/20-mai...sump-plug.html
Thanks Chuck. I was actually taking a look at this yesterday as soon as I saw how much metal was on my plug.

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Originally Posted by theknurl View Post
Smoker;
I'd do a real good job of bleeding the clutch.......if that doesn't fix it look at the clutch pack
then I'd drop the oil pan and check the idler gear and bearing
If the transmission isn't making noise I doubt that's the problem

Thanks Noel. I actually did bleed the clutch in the Fall after I did the valve clearance check. It did improve but the fluid was very cloudy (previous owner never changed it). It wouldn't hurt to give it another flush of clean fluid.

Quote:
Originally Posted by jimboF4 View Post
Smoker,can you please confirm model and year, current mileage also what oil you running and idea of oil change intervals, I guess there was no sign of anything like this the last change?

Certainly something amiss and worth following Noel's advice for next steps.
2011 B4 1090RR with 12,xxx miles. I've changed the oil two or three times since I've had it so on average it is changed around 3k miles or once a season. I can't speak for how often the previous owner changed it. I run 20W50 (I don't want to start another "best" oil thread!) No, I did not notice metal shaving like this on my last oil change.

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Originally Posted by RobR View Post
Mate that was me. Long story short. It was the bearing on the lower cam chain gear. Same amount of metal. And I will bet there will be heaps more metal still trapped in the sump which you will have to drop and clean.

You can pull the clutch and gearbox for piece of mind, but if I was you I would take off the rocker cover and if you have access to an inspection camera (USB camera a few bucks on ebay) stick it down through the top until you can see the gear. Then rock the crank back and forth slightly using normal hex key for engine rotation and you should be able to see the gear twist off its axis because if the bearing is gone there is about 2mm of play between the gear and shaft.
If this is the problem you have to go in from the top. I removed the engine but Eddypro stripped his B4 by just lifting and supporting the front end.

Hope this helps.
Rob
Rob,

I went through your whole thread yesterday. I'm hoping it's not the same issue but our metal flakes do look eerily similar. I get to work with problematic crankshaft suppliers at work so I'm sure i'll be lucky enough to deal with it at home now.

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Originally Posted by silentservice703 View Post
@Smoker: Justin, I have a fiber optic camera I can send your way. You actually might have access to one in the "shop" of yours......
You are right about that Chuck. I actually have a borescope for my phone that I can get out.

Thanks for the feedback everyone. I'm going to clear out some space in the garage and get to it. I was looking forward to a season with little maintenance and lots of riding. So much for that!

I probably won't be able to pull the clutch today since I don't have anything to hold the hub with and I don't have an impact to try it without the hub tool.

2011 Brutale 1090RR
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post #8 of 61 (permalink) Old 02-19-2017, 10:30 AM
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@Smoker...you want me to send you my clutch basket tool?

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post #9 of 61 (permalink) Old 02-19-2017, 12:33 PM Thread Starter
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@Smoker...you want me to send you my clutch basket tool?

[iurl="http://www.mvagusta.net/forum/attachment.php?attachmentid=371481&d=1487518210"][/iurl]
Thanks for the offer Chuck. I should be able to get my hands on something from work or else I can get something fab'd up quick. If not, I'll let you know.
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post #10 of 61 (permalink) Old 02-19-2017, 01:55 PM
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Good Luck!

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