23K+ Km And A Possible Dct Failure?

Sunday 03.03

So...there I was....on my return trip from a Biker Event about 1000km from home.

About 200km to go I start feeling a very very slight vibration through my handle bars.

I stop my music and start paying some more attention to what's happening to the bike. I listen but can't really hear anything.....I am doing about 150km/hr. Slow down some and the vibrations increase.....I can also hear a strange sound. My first thought are of my front wheel bearings.

So I slow down some more and come to a stop to have a closer look at the front wheel. Strange thing happens as I come to a stop..the bike goes off. Oh well, what to do. I get off, put the bike up on the centre stand and have a look/feel of the front wheel. All appears ok. So I start the bike again and the knocking/crashing/grinding sound that greets me causes my heart to sink.

I am not going anywhere now....well at least, not on the VFR.

Hire a minivan and load her up. About 2 hours later I am home and she is standing on the driveway. I can't bear to listen to her again so I go in and call it a day! But as I go to sleep, I am filled with thoughts of having to purchase a new engine! Sleep doesn't come easy!

Monday 03.04

Get to her and start a visual check.

Oil level? Check

Water level? Check

Electricals or DTC? All good

So I start her up again.

The noise is terrible...but I listen on and I am pleasantly surprised to hear that the sound appears to be coming from the rear of the engine/gearbox assembly. perhaps the engine is OK and its just a shaft or bearing in the gear box? I engage first and the response is normal and as would be expected.

So dissassembly starts! I figure that I might be able to do some investigation from the sides. Taking the clutch cover doesn't reveal much....and I realize I have no choice that to take the engine out of the frame and open her up.

As the day end I ponder on what might be wrong. Starting from what I know

1. noise comes with the engine running

2. gear selection appears to be "normal"

3. noise appears to be coming from the rear of the engine/gearbox assembly.

I figure that its either the countershaft or the main shaft thats screwed up.

Tomorrow, I will share what I found.

Uploading the video with her running this morning. Will share the link when the upload is ready.

Has anyone had any experience with the DCT like this or similar?

Still trying to upload the video...we will see how that goes.

So the pictures say the story.....for now.

Fillings in the sump. Strange because I have only every serviced the bike with genuine Honda filters and I use the synthetic oil recommended by the shop I bought the bike from (I actually bought 6 4-liter cans along with the bike). My service interval is 5000km and I always change both the oil and the DCT filter.

What could have gone wrong???

[image: post-15902-0-61839400-1362490767.jpg]

[image: post-15902-0-25854500-1362490791.jpg]

[image: post-15902-0-26832700-1362490808.jpg]

[image: post-15902-0-69652400-1362490836.jpg]

:unsure:

Oh no... That doesn't look good.

Very curious to see what comes of this when you pin down the cause. What a shame. :sad:

Wow! I'm really sorry for that. No extended warranty? I'd be beyond pissed. You seem to have the know how and a level head. Better than me you are.

It is with a heavy heart that I inform us all of the worst.

I have a damaged crack-shaft.

Piston 1 appears to have lost its bearings somewhere along the line and the pictures say the rest.

[image: post-15902-0-58823500-1362497990.jpg]

[image: post-15902-0-48926600-1362498022.jpg]

[image: post-15902-0-69547900-1362498034.jpg]

That's absolutely awful news! I'm so sorry you're having such serious problems! Is the bike not under warranty?

That sucks!

I hope you have warranty coverage for this.

I'd be interested in finding out if anyone else has reported a similar issue.

Best of luck to you in getting this sorted out.

I guess you are aware of the issue some of the early bikes had with swarf in the engine left over from the manufacturing process? No idea if this is what's happened in your engine but is it possible swarf may have blocked an oil feed to the big end bearing? Some of those chips in the sump look quite big to me.

I think I'd be contacting Honda directly on this one.

Oh man... That's rough. :sad:

Keep us posted on the fix.

Stroman

I guess you are aware of the issue some of the early bikes had with swarf in the engine left over from the manufacturing process? No idea if this is what's happened in your engine but is it possible swarf may have blocked an oil feed to the big end bearing?

What's that all about Stroman?

Thats terrible HAND BUILT MY A$$ !!!!!!!!!!!!

I think if he still had warranty, he would not have disassembled the bike in the first place.

Sorry for your luck.

Maybe if the damage is only confined to that one bearing, if you are lucky, you could get the crankshaft turned down, and use an undersized bearing, thoroughly clean the rest of the engine, and reassemble.

You didn't ride it too long after the noise, so perhaps it's possible to save it.

Yokel, there was a batch of early bikes recalled in the UK for inspection by Honda after they discovered swarf in some engines. I think the technicians checked the oil ways with a boroscope. Not sure if it applies to models sold in the US. Lots of threads on the problem if you Google it.

From Honda:

Honda is aware that some customers have experienced an abnormal engine noise with their VFR1200F.

This was referred to Hondas technical team for investigation, who found aluminium swarf (small shavings of metal) present in some VFR1200F engines. This issue potentially affects only VFR1200Fs manufactured over an identified and specific period of time. In total there are 392 potentially affected machines in the UK.

Honda has notified VOSA and a recall is now in progress for the selected VFR1200F models, as the swarf could cause a potential problem with the engine and, in the worst case, possible engine seizure, due to the aluminium swarf restricting the engine oil passage in certain conditions.

All registered owners of possibly affected machines will be contacted by Honda shortly and advised to contact their local authorised Honda Motorcycle dealer.

An inspection of all the potentially affected machines will be carried out by checking the oil gallery for aluminium swarf. If no swarf is found then no further action will be necessary. If any swarf is found a new replacement engine assembly will be fitted.

Honda would like to reassure that our customers concerns and our engineering quality standards are taken seriously and treated as priority and we apologise to customers affected by this issue for any disappointment or inconvenience caused.

Should customers have any further concerns, we would advise them to firstly contact their local Honda dealer or contact Hondas Recall Line on 0845 200 8002, open from 8am to 6pm Monday to Friday.

You have been swarfed.

Even if it is out of warranty, I would file a complaint with Honda. You never know. They have reps with policy money and could always get an engine out of the deal because of the low mileage. Or maybe 1/2 the cost of a new one or something. It's worth a shot.

:1: ,000

Definately contact the local Honda Rep.

You may be pleasantly surprised by what Honda does to stand behind their product and those who purchase it.

Good luck man. I hope Honda does come through and provides at least some type of concessions.

Thanks for the support guys!

Several constraints I have.....I am Nigeria in Africa.....bike was bought from a dealer in the UK.

Apparently, my warranty is only valid in the EU zone.

However, my dealer, Doble in the UK, has promised to see what can be done so I am hoping for the best. I dont even want to think of having to rebuild that V4 lump.

Good luck. I suppose it's possible your bike missed out on the recall with you being overseas. I bought an early dct and rang Honda at the time providing them with the chassis number, they confirmed that the inspection work had been carried out. Might be worth a call so they can check if yours was one of the affected batch, or perhaps Double can do it for you.

Is this the first one of this kind to happen?? I haven't heard of any others...

My buddy's Kawasaki ZX-12r ate a main bearing just outside warranty. Apparently some of the bikes had tight bearings fitted at the factory.

He contacted Kawasaki, and they provided free parts, he paid for the dealer's labour. Better than nothing.

Rotten luck mate, I hope someone can come to the table and help you out.

Failing the dealer in the UK, I'd be inclined to write to Honda (UK/JP) directly.

BTW...made a video before I opened her up.....its not the best of videos but its here

I couldn't listen, had to turn it off as it was so awful. Worlds first diesel VFR1200F?

Here's hoping it's sorted for you soonest.

Peter

Man when was the last time anyone saw a VFR with a chewed up crankshaft, eh? A rare thing indeed, and it looks like Honda really did have some machining issues with some early bikes.

Glad I didn't buy one of the leftover 2010 VFR1200s - if the 2012 model was here I could have easily bought one of those over the K1300R at the time.

WOW dont know how it stayed together.

Listening to the video i am cringing knowing it's a barring...TURN IT OFF! lol. I probably would have thought it was the DCT as well, I wouldn't have even thought it was a main barring!

I think it is a rare thing in any motorcycle to throw a piston barring considering they are designed to such fine tolerances.

Safety Recall

Engine Abnormal Noise

http://www.hot.ee/ripper33//VFR%201200%20recall%20list100529013706177_ESB220100003.pdf

Interesting...the bulletin says the DCT version is not affected. Although my VIN is in the range....001235.

The pic with the busted bearing in hand says it all.

The video is the one two punch to the gut. :ohmy:

I would hope Honda stands by their stuff in this case.

Regardless of if it's officially under warranty or not.

What a bummer. :dry:

Do make sure that Honda UK/EMEA/WW is made aware that a few 1,000 of their VFR customers are following this on VFRDISCUSSION.COM

Customers that are keen to learn if Honda stands by their product. Irrespective of where it was ridden or who took the engine apart...

good luck

edited

Dutchy

Do make sure that Honda UK/EMEA/WW is made aware that a few 1,000 of their VFR customers are following this on VFRDISCUSSION.COM

Customers that are keen to learn if Honda stands by their product. Irrespective of where it was ridden or who took the engine apart...

good luck!

lknsdvoinbpoissdpojp

oskd ncoisndppndcpon owinc[oido[in]0indec poimned0iohjwe]0992

ME TOO !!!!!!!

Fotodadi i hope Honda will supply you a new engine. Good luck.

Looks Like I have a long battle ahead of me.

Below is Honda UK/EU's reply and my email.

Dear Mr Kanu

Thank you for your recent e-mail into our offices regarding your Honda VFR1200. I am sorry to hear of the recent problem that you have experienced with your Honda VFR1200.

Honda (UK) provide a warranty of 3 years from date of first registration on this motorcycle and it is with regret that you experienced this problem. The 3 year warranty is valid whilst the motorcycle is within the UK or EU and it would appear that the motorcycle is now used in Nigeria. Therefore, any warranty on the motorcycle is no longer in place.

With regards to a recall on this motorcycle, there are no recalls showing on this motorcycle as being outstanding therefore it is unclear which recall you feel is outstanding. At this stage, whilst sympathetic to your case, I am sorry to have to advise that Honda (UK) are unable to assist with this matter further.

Honda (UK) values all of the feedback that we receive into our offices as information of this type is used to improve the range of products and services that we provide to our customers and it is with regret that on this occasion your personal expectations have not been met.

Thank you for taking the time to contact us.

Kind Regards,
Sarah



Customer Relations - Cars
Customer & Aftersales
Honda (UK)

Telephone: 0845 200 8000




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solely those of the author and do not necessarily represent those of Honda
Motor Europe Ltd. or any of its group of companies.

If you are not the intended recipient, be advised that you have received
this email in error and that any use, dissemination, forwarding, printing
or copying of this email is strictly prohibited.

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register number 311813.

Visit our website: http://www.honda.co.uk
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"Ogbonnaya Kanu" ---08/03/2013 13:52:26---Hello CS, Following my call earlier today, kindly find pictures of the engine damage

From: "Ogbonnaya Kanu" <ogbonnaya@seindeo.com>
To: <customer.servicecars@honda-eu.com>,
Date: 08/03/2013 13:52
Subject: Case Ref 934264
Sent by: Ogbonnaya Kanu <oekanu@gmail.com>

Hello CS,

Following my call earlier today, kindly find pictures of the engine damage to my VFR1200FD along with a link to the video of the engine (and its operation) prior to disassembly. http://s856.beta.photobucket.com/user/fotodadi/media/VFR1200FDGeargoingbad.mp4.html?sort=3&o=0

<<...>> <<...>> <<...>> <<...>> <<...>>

As I have mentioned earlier, I would like to order a new VFR1200FD, 2013 model in Black and receive a new engine to replace this failed one.

I do look forward to your speedy resolution of this problem.

Best Regards

Ogbonnaya Kanu

Bummer, I think it might be time for us on VFRD to help this guy out. Maybe if we all sent emails to the above address and expressed our disappointment with them maybe he could get some resolution... Squeaky wheel... :mad:

crazybrother

Bummer, I think it might be time for us on VFRD to help this guy out. Maybe if we all sent emails to the above address and expressed our disappointment with them maybe he could get some resolution... Squeaky wheel... :mad:

I just wrote them to let them know of my dissapointment.

Hello. As a longtime Honda motorcycle owner (30 years, and never owned anything other than a Honda brand motorcycle), I am writing to you today in hopes that you will raise the bar in terms of your customer service and satisfaction experience.

As a member of a very large online worldwide VFR owner's community, it has come to my attention that one of our members, Mr Ogbonnaya Kanu, has has an issue with his VFR1200.

see: Honda Case Ref 934264

There has been an unfortunate engine failure, the root cause of which is detailed in Honda's own service bulletin here:

Bulletin No ESB220100003

Mr Kanu's VIN number falls within the range specified in the service bulletin.

Honda's rationale for denying his claim is that he is currently residing in Nigeria. I believe this amounts to discrimination of a geographical nature. As long as the vehicle has been maintained by the owner, with the specified maintenance intervals being observed, I see no reason why his motorcycle should not be covered by the service bulletin, which clearly states that swarf in the engine during the assembly process can cause engine failure, and a replacement engine will be provided.

This is a Honda factory quality control issue, and it would behoove your company to handle this in a manner that will instlll renewed confidence in the Honda brand, both for Mr. Kanu, and also for the tens of thousands of Honda VFR owners around the globe who are watching and waiting for your favorable response to Mr. Kanu's situation.

I myself have suffered a debilitating ankle injury which hampers my ability to change gears on my motorcycle, and at one point, I had considered a Honda VFR1200DCT as a possible solution to this problem. However, if this engine failure, and subsequent refusal of Honda to back their products is any indication, then I would not be inclined to purchase a DCT1200 at all, new or used.

I challenge you to escalate this claim beyond your front line service personnel, and bring it to the attention of someone higher up in the organization who can assist Mr Kanu in obtaining a replacement engine for his VFR1200. It's the right thing to do, regardless of policy regarding the UK/EU operating area.

What if one of your customers bought a VFR1200 in the UK, and then set off on a world tour? What if it suffered an engine failure halfway across Canada due to swarf in the engine?

The facts are this: Mr Kanu bought a NEW motorcycle from Honda. Honda admits engine quality issues with the motorcycle. Honda refuses to back it's product even after admitting the root cause of the problem.

Please do not continue to hide behind corporate policy as a reason to not provide a reasonable remedy for your customers and correct problems that have existed in your factory, and been common knowledge since the VFR1200 was introduced.

Do the right thing.

Rob McKinnon - VFR800 owner

5 Windfall Drive

Whitecourt, Alberta, Canada

if anyone else decides to write, make sure to include the case number, his name, and the service bulletin, so that Honda can connect all the correspondence.

Fotodadi, you may wish to contact the Honda service manager in Japan also:

Motorcycle Service Engineering Dept.,

Motorcycle Customer Service Div.

Honda Motor Co., Ltd.

3-15-1, Senzui, Asaka-shi,

Saitama 351-8555, Japan

Reference Attn.: Mr. Takao Tsuboi, Service Manager

he was listed in the service bulletin.

Sara is the person who just types in your vin and on a standard letter of "so sorry to hear your problem". I have seen many of those in my lifetime from customers who hit the same roadblock. Worst yet, she works in the car division.

As Rob mentioned, contact the Service Area Manager for the UK region as well as the Service Manager in Japan. If possible try to get both of their emails and CC them both. If you send a letter, make it "signature required" by that individual(s). Hammer them.

I will also send in a letter for your support and that of any other individual. No matter if the bike is currently under warranty or out of warranty, in the serial number or outside the VIN recall. Honda failed to keep the quality of their production line to the high standards they claim and admitted there is a problem. Pretty hard to push any new bike that comes off the line when your new VFR has a major issue and your telling those customers they are just SOL.

If not done already, the UK dealership should vouch for you that you are a real customer.
"Nigerian" has become synonym for "scammer" unfortunately...
If Honda UK wants to see you are real, they should set up an appointment with the Honda Nigeria director of sales in Lagos.
For you to show the purchasing document.

Honda UK's e-mail is the normal "computer says no" response, happens all the time.

You get what you accept,
do not accept this....

Dutchy has made a very good point.

Meet with Nigerian representatives from Honda, show purchase receipts and any other pertinent documents, in other words, make sure that there is no question of legitimacy. Then, enlist Nigerian H reps in reaching out to Honda UK.

It would be in Honda's best interest to act in good faith and show that it stands by its products and its customers. Especially since this particular bike is the flagship of the brand and commands hefty price of admission.

In my experience use the contact information for the service manager in Japan. The rest of the world will try to get out of warranty repairs by default. Japan HQ tends to take these things more seriously, at least they used to. I've read several accounts, over the years, of Japan HQ laying down the law and fixing busted bits in NA when the NA rep. denied claim.

good luck to you sir.

Ah, the infamous Nigerian blown engine scam. :goofy: :laugh:

Would be good publicity for Honda, and relatively cheap as those things go.

A few $$ grand? Verify it's legit, and give the guy the benefit of the doubt first so you can check. :warranty:

Or, they can let you guys stink up the joint. :pissed: Good plan. :laughing6-hehe:

I would put it back together and sell it off for a new Yamaha FJR. I have worked on the OEM side for years and agree with other posts that you are getting shafted here. Worst case Honda should have covered the replacement parts and you covered the labor. Their cost on the parts is very low, and if I were the customer it would make me a raving fan for life that they stood behind their product. After all this is their flagship bike supposedly. They didn't, and if I were in your position, I wouldn't buy another Honda ever.

Try as others suggested to contact Honda Japan. As the disclaimer below the email says, the answer you got is striclty that of the person that happened to be sitting behind the computer at that time, not that of Honda (Huh?)

Any views or opinions presented are

solely those of the author and do not necessarily represent those of Honda

Motor Europe Ltd. or any of its group of companies.

Dutchy

Honda UK's e-mail is the normal "computer says no" response, happens all the time.

http://youtu.be/0n_Ty_72Qds

Good luck sir. I hope that you are successful.

fotodadi

fotodadi, on 12 Mar 2013 - 07:35, said:

Thanks so much for all your help, suggestions and advice.

I have just gotten the final email from Honda UK and I am tired and will not pursue it any further.

Honda, UK, have told me that it is out of warranty and thats that.

Have just completed ordering all the parts I will need to rebuild....I have decided to go with a new crank...and will keep you all updated.

But, I can understand your wanting to quit chasing after them, just move on, and rebuild.

Best of luck with it. Sounds like you have the know how and tools.

And you know, we do like a good build thread around here. With pictures. :warranty:

Edit to add...

V4Rosso, that is hilarious. LMAO.

Customer Service survey, I choose C. :laughing6-hehe:

First figure out why the bearing did go out . Is there an obstruction in one of the main oil bearing supply chanals ?

Clean the engine very very good !!! Use new conrod bolts !!

This is actually what has me very very concerned......."Why did this happen?".

I have observed that there was no discoloration on the crankshaft, con-rod or metal bearings. This leads me to the conclusion that the failure was unlikely to have been caused by a lack of lubrication. If there was lack of sufficient oil flow, there would have also been local overheating so that the metal would have been discolored.

Right now, I have sent the pictures and the video on a CD by courier to Honda Japan. I am hoping that someone will take an interest and perhaps eventually, I will get all the parts for free? At the time I decide to rebuild, I will be stripping the engine and cleaning thoroughly, all the oil channels.

Before that I welcome suggestions and ideas on possible angles as to the cause.

Yeah just like the early Magna's with the cam bearing and cams failures.

Acouple of thousand of VFR riders are following this topic with interest................

Good on ya.

Keep pushing this channel. I'm telling you, you rattle some heads in Japan, and shit happens. They do not play. Honda may not be the Honda of old but Japanese culture is very different than European culture, and they tend to take these types of things very seriously. You will continue to have to jump through hurdles but in the end I think they'll support.

Good luck to you sir.

I've been following this also with anticipation that Honda will do the right thing,

There's a difference between normal wear and tear, abuse and defective, this is an obvious defect in the product, a lemon as is known in the auto industry and Honda would do itself a tremendous service by making things right.

Finally sounds like you are getting somewhere with Honda.. Best wishes going forward!

About time HONDA ...

Dutchy

Acouple of thousand of VFR riders are following this topic with interest................

All over the world...

Good luck!

A new engine and tech support repairing the bike.

That would be an honorable thing to do. :warranty:

Hi fotodaddy,

While it is encouraging to hear from Honda about your dilemma, it is not good practice to post all of your direct communication on this or any forum. It can potentially sour any goodwill between you and the other party. Transactions of goodwill should be kept private lest it jeopardize future instances of goodwill. If Honda or any mfgr of goods sees its actions broadcast like this, it will be less inclined to do so in the future simply because it establishes the perception that this is now legal obligation for any such instance when in fact they are acting beyond their legal obligation. Furthermore, from a cultural perspective, the Japanese and most Asian cultures expect confidentiality in the business dealings. Violating their trust can scuttle the best of intentions. IMHO you would do well to keep a lid on it.

Update.

In the last 2 weeks, Honda have surprised me further with the care and concern they have shown.

I even got a visit from reps from the local assembly plant (assembling 125s and petrol generators) who took pictures and asked questions and stuff.

Good news soon?

We will see.

Sounds GOOOOD !!!!!!

Maybe you'll get ten 125's? :goofy:

[image: 2649028-622868-row-of-motorcycle-wheels.]

Good to hear Honda now shows interest in your case :fing02:

Dutchy

Maybe you'll get ten 125's? :goofy:

[image: 2649028-622868-row-of-motorcycle-wheels.]

Ha ha ha!

Now that's really funny!!!

Some progression ?

I have received quite a few emails and phone calls. All seem to be pointing to a happy ending for this story.

When it happens, I will share with all.

Fingers crossed! :fing02:

Good Luck .....

Yay! :cheerleader:

Hmmmmm!

What I can say is that it is not very easy to process imports into Nigeria. What with all the documentation that one has to do.....especially if such an item has never been imported before. :wink:

I am loving HONDA :cheerleader:

More details please!

And if they are giving you a brand new bike, major congratulations!!!

It would seem at least one was imported before. :cool:

Or maybe Hoda thinks a Cross Tourer is a more suitable bike for Nigeria.

BUMP!!!!!

Hoping to read the good news........ :cool:

What can I say!

A picture is worth a thousand words.

In this case....several! Honda came through for me BIG TIME!

[image: IMAG0926.jpg]

Hmmmmm...what do we have here!

[image: IMAG0929.jpg]

Hmmmm....a HONDA Van!

[image: IMAG0927.jpg]

Ahhh....A Box

[image: IMAG0930.jpg]

Looks like an engine.....could it be?

[image: IMAG0933.jpg]

Ohhh yes.....a brand spanking new HONDA VFR1200FD Engine!

[image: IMAG0973.jpg]

Getting reday for heart "transplant"

[image: IMAG0982.jpg]

In progress.....

[image: IMAG0983.jpg]

More progress!!!

[image: IMAG0984.jpg]

End of day 1.

Bravo Honda HQ, to step in where Honda UK didnot want to know....

WOW!!!!! GO HONDA.

It says on the side of the van: "More durable engine"

Let's hope for FotoDadi that it is.

So excellent that they finally helped you out.

So now you have TWO of them, since you had bought a replacement bike already, what are you going to do?

Veefer800Canuck

ISo now you have TWO of them, since you had bought a replacement bike already, what are you going to do?

Have a friend who is just waiting for it to be assembled to take it off me. :cool:

Finally she is up!!!

FEAR ME (2010 model) meets ROLE MODEL (2013 model)

[image: IMAG1003.jpg]

:cheerleader:

Congrats dude.

Glad that the Mother Honda took care of the problem.

Now what you have 2 VFR1200 ?

So some techs in flip flops show up with a motor in a cool Toyota van (that I wish we could get here in the US) and do a back alley transplant? AWESOME! It reminds me of a Top Gear episode where they ride scooters through Thailand and one of them gets a new/used Vespa motor tossed in by some guys squatting in the mud chain smoking Marlboros. Congrats on making Honda fess up. Since they've started adding freight and setup to all of our bikes here in the US they should have lots of cash laying around to stand by their products. Interesting that they didn't come in a Honda van.

I bet some of the best mechanics are the ones not specially "trained" by the big car and motorcycles companies.

I bet these guys in the farther corners of the world, working in "less than ideal" conditions, will never let a Honda "special tool" requirement from getting the job done! :rolleyes: :fing02:

Very FotoDadi that they came through!

I am sure your mate will take the '10 off your hands now after seeing the new engine, no problem.

Beck

I bet these guys in the farther corners of the world, working in "less than ideal" conditions, will never let a Honda "special tool" requirement from getting the job done! :rolleyes: :fing02:

:laugh:

I had nightmares after seeing those pictures of that bike gutted like a fish......

Glad things turned out well.

Unfortunately, now I have exectly the same big end problem with my vfr dct 2012.

My question is this: to get to the bearing shells in order to replace them, obviously must split the crankcase. Honda requires that everything must be taken off, included cylinders and the drive unit and complex coupling

Due to a lack of special tools to get those parts dismounted properly, I hope to be able to split the case with the clutch and cylinders in place and only took out the bolts of the bevel gearbox, because its mounted just over the breakline. After this I thought to be able to split the case as well.

But despite of having all the all bolts according to the manual out, I can’ t get the scales split up, even with a bar I putted some force say 70kg to it, but the space at the edges never got more then say ½ mm, so it looks like there is still something holding it together, somewhere at the place where the bevelgear unit is situated.

Does anyone have experience or a tip on how you get the block opend up without force/ damage.

The problem is of course that I do not have all the special tools, but I suppose in Africa you had them either who did you manage ?

RobbieRabbit

Unfortunately, now I have exectly the same big end problem with my vfr dct 2012.

My question is this: to get to the bearing shells in order to replace them, obviously must split the crankcase. Honda requires that everything must be taken off, included cylinders and the drive unit and complex coupling

Due to a lack of special tools to get those parts dismounted properly, I hope to be able to split the case with the clutch and cylinders in place and only took out the bolts of the bevel gearbox, because its mounted just over the breakline. After this I thought to be able to split the case as well.

But despite of having all the all bolts according to the manual out, I can’ t get the scales split up, even with a bar I putted some force say 70kg to it, but the space at the edges never got more then say ½ mm, so it looks like there is still something holding it together, somewhere at the place where the bevelgear unit is situated.

Does anyone have experience or a tip on how you get the block opend up without force/ damage.

The problem is of course that I do not have all the special tools, but I suppose in Africa you had them either who did you manage ?

Did you find any of the aluminum bits in the sump as was found to be an issue with some 2010 models bought in the UK?

How many km on the bike?

The bike runs 52000km/32000miles, the oil was full with metal chips

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WOW!!! I am just seeinf this.... I am so sorry about your experience. I really do not remember having any problem splitting the engine like I did without any special tools. I do remember that I had some difficulty around the drive out of the gear box.

So how is it with you?

....and the bike is still going strong 6 years and 43,000km down the line. 

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Ouch....that's a decent sized dent in the back rim you have there..! :blush:

Smaller one on the front too...pot hole...dog....cattle..!..??

Smithy.

10 hours ago, ausmithy

Ouch....that's a decent sized dent in the back rim you have there..! :blush:

Smaller one on the front too...pot hole...dog....cattle..!..??

Smithy.

Pot hole!! 

Came across this one in Nepal (many years ago, still have that umbrella!) :-)

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