Bad Day for the Big Kahuna :(

[Big Kahuna]

Well, I've been waiting for this weekend for some time. Getting out on the blade and hitting the first annual BBQ at Yamaha99 in Madera.

I had some time to kill so I thought I 'd take the bike out to one of my favorite roads, the "Little Dragon" to test out the new suspension settings that Dave Moss gave me last week.

It was a beautiful day, little traffic and no LEO's anywhere to be found. About a half mile from Fremont's Fort, the head of the little dragon I hear a blimp, clank, followed by a swoosh... I look down to find my chain is now missing. I pull off the road and give HRCA a call with what little cell service I could find. I'm walking up and down the road in the middle of nowhere trying to find a signal... Finally got a hold of them, and after a lengthy call to a few local dealerships, they finally call a tow truck. I was stuck there on the side of the road, no food nor water or shade for the next 2.5 hours. I thought at least that everything would be alright, just needed a new chain because my road side inspection revealed no leaks or damage so it seemed.

When I finally got home and was able to take a better look around and I quickly found out that my worst fears have come true. When the chain went bye-bye, it left some big gouges in my swing arm. But worse than that, it tore up my crank housing and busted up the engine case pretty good.

733 734 735

I am monotonous about my chain maintenance, and the thought of me suffering a major breakage was almost inconceivable. I have no idea what it is going to take to fix this, or even if it can be repaired. Either way it doesn't look like I'll be heading to Laguna this year, at least with the Repsol. :(

[MeanMachine]

Really sorry to hear this man. I don't even know what to say. Could have been worse, at least you did not get hurt.

[jbigelow]

sorry to hear about your bike.....good thing is that you are OK.

cant wait to hear from you when she is ready to go again!!!!!!!

[Ultimate Repsol]

Damn man that is terrible, do you know exactly what caused this problem , was it a defect from the factory or what?:(

[diel11]

I couldn't tell from the pics, but did the chain break your crankcase? If it did that really sucks. I've seen people weld holes in crankcases if they're not too big but I am not a fan of that. Sorry about the bad luck.

[silvercbr]

:( First off, that completely sucks! What type of chain were you using, a 520? I am by no means an expert, or claim to be, but my buddy told me to stay away from 520s on a liter bike. He is an amateur racer and run both 600s and 1000s on his team, well long story short, he told me to stay away from 520s on my liter bike because the power abuses the chains something fierce. Is this correct for street riding as well, or just for race bikes? Like I said, I am no expert and that really sucks.

Parts can be replaced, just thank god it didn't wrap around your rear wheel and cause you to crash. Thinking of ya man, hopefully you can get it fixed ASAP.

[Repsol Robert]

Sorry man! It looks like it didn't crack the case open, or am I mistaken?

I hope it can be repaired without any gymnastics with the motor. I can't imagine why chains pop, never happened to me, and I run my 520 hard.

Let me know if there's anything I can do to help.

RR

[yamahonda]

That's crazy man, I'm sorry to hear that. I've never heard of this happening. Like others have said already its just good you weren't hurt, physically anyway. One thing I know now for sure is to pull over immediately if I hear anything funny on my bike while riding. Sounds like you didn't even get the chance before it was too late. I know a true rider like yourself will find a way to be on two wheels again in no time though;) Stay up bro!

[Big Kahuna]

Thanks everyone...

I was using the stock 530 chain, I had no warning, it just went whoosh and the RPM's rose. It didn't crack the case, but it chewed up the crank housing, and I think broke open the clutch shaft which I believe needs to be sealed.

I was okay with it until I got home and saw the damage. I do still have the '98 so I still have a bike to ride, just not the Repsol. :(

[vcx10]

hi to everyone. i had a gsxr600 1998 before i got my repsol and my chain jumped off my back sprocket at 100mph.it twisted the chain but didnt lock the back wheel on roadside inspection it looked like no damage but when i got it home the chain had broken the mounts off the engine that held the clutch cover on so when i pulled my clutch in the cover got forced off the engine so no clutch.to sort it i drilled the cover and bolted a strip of metal onto it and then removed a big bolt that went into the engine and drilled the metal strip put the bolt back in and it worked fine. i always keep my chain at the correct tension after that.

[scudafi]

Thanks everyone...

I was using the stock 530 chain, I had no warning, it just went whoosh and the RPM's rose. It didn't crack the case, but it chewed up the crank housing, and I think broke open the clutch shaft which I believe needs to be sealed.

I was okay with it until I got home and saw the damage. I do still have the '98 so I still have a bike to ride, just not the Repsol. :(

When you say Laguna, do you mean the MotoGP? It's not till mid July.
What would stop you from fixing this, and taking the Repsol to Laguna?

[psuntlion]

Wow Kahuna - sorry to hear about your calamity! How many miles did you have on the chain when when it let go?

[MeanMachine]

Curious, did you recover the chain? Was the lock link still intact or did that let loose?

[Belch]

Good to hear your OK. If you can find a good TIG welder he should be able to fix any cracks or chuncks and it will be just as strong as new.

[hondapowered]

Holy Christ... I almost puked when I saw damage to your girl :mad: I hope things work out for you soon, sorry to hear about your misfortune... I am glad to know the big kahuna did not get hurt, at least the chain exited mostly safe and did not hurt you....Your girl will be happy when she gets patched up....The positive side for people on the forum is that they will get to hear how the whole thing pans out and with the info you get out of this you might save somebody's leg or help them avoid a high speed crash due to the same type of mechanical failure....I know you will recover quick , you keep a BIG KAHUNA down `Onipa`a.

Stand firm>>>>>>>>>

[Big Kahuna]

While waiting for the tow truck, I went back to look for the chain, but couldn't find it. On the way back in the tow truck I did see it on the opposite side of the road. It's about a 45 minute drive back there, but I'm going to see if it's still there tomorrow. I would like to know where the chain broke loose.

The main problem I'm seeing is, there are three bolts that hold the sprocket cover on. The clutch thingy then sites on the cover and activates the clutch by using a long metal rod. I know at least one of the mounting points was torn off, but I still have it as I found it lying there loose when I got home. I think I probably can reattach that somehow but the top mounting bolt came out with the little screw threaded thing attached. I'm not sure if the two mounting bolts would be rigid enough to make sure the clutch thing fully engages.

The funny thing is, I just purchased a "Nicky" modded sprocket cover which came with the plate and gaskets, so I already have the parts to replace those damaged in the incident.

It doesn't look like it cracked the case, only took off some of the protruding edges around the sprocket cover. I'm not sure, I'll have to have someone look at it to see what needs to be done. By looking at replacement costs for a new case, not counting the labor, it will be some time before I will be able to get it replaced. I do have a Honda card but have to use that at a dealer. I don't know if I trust a dealer around here with my bike.

[Big Kahuna]

The chain had just over 8,000 miles on it. I did forget to mention that when I had the tires new wheels put on, we took the chain off. Can't remember why at the moment, maybe because I was thinking about going to a 520 setup but decided to keep the stock setup. I had to run out and get a link from a different manufacturer but it was a 530 and fit the chain. I had just purchased a new stock link a few weeks ago as I was going to change it out just to be safe, but I never changed it out.

I just had a new tire put on after getting a piece of glass in the old one, so I had just adjusted and lubed the chain a day or so before the incident.

I'm hoping that I can recover the chain and find that master link still intact, or else I'm probably going to hang myself.

[MEGA]

Damn dude...i feel your pain.
Well at least your other bike gets the attention its been lacking since you got the repsol..Ride away!! Your sexy Rep will be back on the road soon enough and your other bike will be collecting dudt again..
Best of Luck.
|-_-| MEGA

[Thrasher]

WOW BK that scares me, stupid chain doing all that damage and from what I hear it could of been much worse Thank God or whoever you didnt get hurt. The bike will heal just more $$ and its just worthless paper no point even thinking about it just make it even better, stronger, faster... hey TV show, remember:D

[cb1974]

Sorry to hear about the mishap. At least you didn't get hurt.

[MeanMachine]

I had to run out and get a link from a different manufacturer but it was a 530 and fit the chain. I had just purchased a new stock link a few weeks ago as I was going to change it out just to be safe, but I never changed it out.

I'm hoping that I can recover the chain and find that master link still intact, or else I'm probably going to hang myself.

BK I think you are going to find the Master Link is gone. Chains do not often fail at places other than the Master Link under normal street conditions. If the chain was old and really stretched and jumped the sprocket and snapped, that is one thing, but with just 8k on the chain I would be willing to bet money that the master Link failed in this case. You keep it lubed and don't seem like the kind of guy that neglects maintenance, it must have been the Master. :(

[6speed]

:( sorry bro

[Big Kahuna]

Thanks for all the nice words guys, it really means a lot to me. I went home at lunch to survey the damage with a little better light. Looks like the upper and lower mounts are still 100% intact. The main thing I'm conceded about is getting the smaller mount near the clutch welded on. It is sitting right next the the case seam, which I hear is not a good place to weld.

Mike (CTSmoto) is going to have one of his guys look at it to see what can be done.

[ZZGIXXER]

Dude sorry to hear about your repsol..... i've riding for almost 18 years...i have never had a chain break on me like that (knock on wood)....one of the major things you may consider lucky on this case....the chain did not break on you while taking a curb on high speed....and if you did you are way way lucky....you have learn your lesson by now. think safety and always check your equipment/unit. be safe and take care of yourself.

[1eyebrother]

man how did I miss this post :( ....sorry to hear about the incident you had this weekend.....atleast you are ok and was only damage to the bike(hope not too much)......you will get her back on the road in no time.....

[hondapowered]

I just wanted to check in and see if there is any new info on your messed up situation? Hope things are going well>>>>>>>>>>> :cool:

[Big Kahuna]

I'm bringing it into the shop this weekend. Couldn't get it in there any sooner. Mike's buddy says it will be no problem to fix, he's done it many times int he past. :D

[silvercbr]

I'm bringing it into the shop this weekend. Couldn't get it in there any sooner. Mike's buddy says it will be no problem to fix, he's done it many times int he past. :D

That is great to hear, thanks for the update!

[hondapowered]

sorry i have been away new job title, but what was the end result with your bike? ohh sorry bout the sink hole on the chrome yellow blade going belly up

[squidracer]

Sorry to hear about what happened. Just curious if the master link you used to put the chain back together was a clip link type or a press on link type. I have had the clip link type and the clips fall off all the time. The press on type master links are the same price and if installed correctly are trouble free and just as strong as the stock one. I had a friend that had an older ZX-7 that used a clip on link on his chain and the chain came off at about 80mph and pretty much shaved off part of the left crankcase and dumped all the oil in a matter of seconds.:eek: From my personal experience and that of others that I know I would STAY AWAY FROM CLIP ON MASTER LINKS!!!!!
Also, if you use a press on master link that is not the same brand as the chain, the pins can be different diameters and lengths even if it is the same size chain.:confused2: Hope you get a chance to get her back together soon!