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Discussion Starter #1
...the dreaded idler gear / broken engine case. A week ago last Saturday I started the bonnie, she idled for a moment then stalled. Not unusual on a cool morning. Pressed the starter button again and there was an awful sound. I had a notion what it was but hoped I was wrong. I was so afraid of what I'd find I didn't remove the clutch cover until the following day. And there it was...damage to the clutch cover and engine case where the idler gear pin is retained. I just can't believe it. Been so depressed I haven't posted about it 'til now.
The bike is a 2001 Bonneville, 790cc with 41k on the odometer. I bought it used in 2007 and have put the last 31k on it. Regular oil changes and the machine's never given me a bit of trouble 'til now and it's in perfect condition except for this. I've been using it as commuter and have ridden it year round except for real cold days, snow and rain. ( well sometimes even in rain). Not sure what to do. I'll probably look around for a later model motor. Right now I'm just posting this to get it off my chest and tell other riders, you know lightning exists but you never think it will hit you....until it does.
I guess the best motorcycle to own is more than one!
 

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chin up and dont despair. from my understanding it is repairable and there has been a post detailing how to do it. do a search and you should find it
 

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Yes, a recent post by a rider who fabricated and screwed in a block of aluminum and installed a new (used) clutch cover. I don't have a link to it, but it looked like a job that any really good mechanic would be able to do. If you're not up to it, print out that thread and take it to Jack at Deer Park Cycles in Eldersburg (MD) and ask if he can do it over the winter.
 

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Discussion Starter #7
Yes, a recent post by a rider who fabricated and screwed in a block of aluminum and installed a new (used) clutch cover. I don't have a link to it, but it looked like a job that any really good mechanic would be able to do. If you're not up to it, print out that thread and take it to Jack at Deer Park Cycles in Eldersburg (MD) and ask if he can do it over the winter.
I saw that. Thanks for the info and the tip about Deer Park. I will check with them about this. Hopefully that would be a lot cheaper than a used motor.
 

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Thanks Marty. I've read that about six times now and I'm pretty sure that's above my skill level. Who was it said a man's got to know his limitations! But somebody can. And I'm lucky this happened now. I'll miss some riding ( 40f and dry pavement is my minimum spec ) but not as bad as the rest of the year. I'll check with Deer Park about it.
 

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I saw that. Thanks for the info and the tip about Deer Park. I will check with them about this. Hopefully that would be a lot cheaper than a used motor.
Deer Park Cycles is worth a visit just to see the old bikes in various stages of restoration. Jack, the owner, is a nice guy and a Brit bike specialist.
 
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