'02 Monster 620 - gear lock & engine whine

[stonescar]

After just getting my Duc back from 28000km service (changing basically everything, $1800 yay) suddenly my gear locked when downshifting from 3rd to 2nd, on my way home from work. I was just a couple of blocks away from home, so I rode it home very slowly and carefully, and killed the engine. I noticed a 'whining' sound coming from the engine, following the rpm, and the gear lever is unmovable.

As the title suggests, it's my 2002 Ducati Monster 620ie., and it's gone about 28kkm.

I'm contacting the workshop first thing in the morning, but I'm so pissed right now - i just need to get an idea of what could've happened.
Any ideas?

Also, can i ride it a short distance to the workshop, or could that harm the bike in some way (whining sound and all)?

[DarkStaR]

Is the noise still on?

Does the noise sound like the starter?

[stonescar]

No, the noise sounds like it's more or less directly connected with the engine revolutions, so it stopped when I killed the engine. Might be from the clutch?

[stonescar]

On second thought, the clutch seemed to be working perfectly even after the incident.

PS
Bah  already one good month of the season has passed (may-oct), and now I've spent all my savings on the previous service. What to do?! Is this something I can hold against the workshop, since they just delivered it from a full service? Or is it just some random mishap that they can't be blamed for? I feel kind of cheated...

[Howie]

Riding the bike to the dealer stuck in second gear might be doable depending on speed and the amount of starts you need to do in second gear, but I wouldn't want to try until I identified the whine.

Unless for some reason they were inside the engine it is most likely not their fault.  Could you post everything they billed you for?

[stonescar]

As the specification is in norwegian, and I'm not too mechanically gifted, I'm not sure I'll translate it right, but i'll give it a try...

From what I can understand they have:

- Changed clutch and brake fluid, replaced rear brake pads
- Changed oil + filter
- Changed valve shims (sp?) + valve adjustment
- Changed timing belt + fan belt
- Syncronised throttle bodies
+ gas filter, spark plugs, some gaskets ++

[Howie]

There is someone on the board who can translate it:
http://ducatimonsterforum.org/index.php?action=profile;u=216

Looks like a normal service, seems like a case of bad luck to me.

[stonescar]

Any clues to what might have happened? How can I identify the whining sound? Can I do anything about the jammed gear?

[ducpainter]

Any clues to what might have happened? How can I identify the whining sound? Can I do anything about the jammed gear?

It sounds like the spring on the shifter assembly broke. I'm not sure about the whining sound.

Are you mechanically inclined at all? Do you have tools?

[Speeddog]

Classic description of a broken shifter spring.



Item #10 in this diagram:



Here's what it looks like in real life:



If the gear lever is stuck in the down position, the top end of the shift arm can be rubbing against the cam drive gear on the end of the crank.

more info here:
http://ducatimonsterforum.org/index.php?topic=32703.0

or search for 'broken shifter spring'

[stonescar]

  Sounds logical. I have a friend a bit more mechanically inclined than myself coming over to help me look at it. A couple of questions:

- I drove for about 2 minutes with the whining sound (but I kept the revs very low) after the gear jammed, could the cam drive gear have been damaged?
- What tools do I need to replace the spring?
- The oil is brand new, can I reuse it after draining, or do I need to replace it?

[Speeddog]

It's possible that it damaged the cam drive gear, but probably not.

4mm allen to remove crank access cover screws.
5mm allen driver to remove the clutch slave and sidecover bolts, as well as a simple/cheap puller to get the cover off.

Using a piece of corrugated cardboard, draw a crude replica of the shape of the sidecover.
Poke holes though it in the approximate location of the bolts, and stick 'em in there as you remove them.
They're different lengths, makes it easier at reassembly.

IIRC, deep 30mm impact socket to get the flywheel nut off, as well as the impact gun.
Torque wrench and red locktite to reinstall, not sure what the torque spec is ATM.

5mm and 6mm allen drivers to remove the shift mechanism.