Sun Mar 27, 2022 8:18 am

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Sun Mar 27, 2022 8:18 am linkquote
I was trying to replace variator weights.

I had seen videos of jamming something in rear wheel to loosen rear bolt.

Applying torque to loosen bolt the casting cracked where it holds the brake assembly.

Not good.

Any idea what part I need to replace and how to do it. Suspect I've made a big tedious expensive job out of a small fun one.

Bummer.


Rear casting near handbrake


Front bolt casting cracked also

Sun Mar 27, 2022 9:13 am

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Sun Mar 27, 2022 9:13 am linkquote
Looks like the brakes attach to final drive cover, not a common part to find spare.
Sun Mar 27, 2022 9:14 am

Addicted
2015 MP3 500 ie Business
Joined: 29 Oct 2019
Posts: 818
Location: Belgium
 
Addicted
2015 MP3 500 ie Business
Joined: 29 Oct 2019
Posts: 818
Location: Belgium
Sun Mar 27, 2022 9:14 am linkquote
The engine block and transmission/rear diff are one single casting.

You will need to seek a donor block.

There is no EZ workaround such as patching/welding.

As far as loosening the rear nut, I always put the bike on the ground with tilt lock enable, parking brake set and apply the rear brake lever with a helper loosening the nut.
Sun Mar 27, 2022 9:38 am

Ossessionato
1979 P150X, 1983 P200E, 1988 T5, 1995 PX200E, 2011 Yamaha Fazer 600 S2
Joined: 02 Aug 2015
Posts: 3113
Location: Veria, Greece
 
Ossessionato
1979 P150X, 1983 P200E, 1988 T5, 1995 PX200E, 2011 Yamaha Fazer 600 S2
Joined: 02 Aug 2015
Posts: 3113
Location: Veria, Greece
Sun Mar 27, 2022 9:38 am linkquote
Replace your final drive cover (OEM code: 8320525) and you'll be fine…



Mon Mar 28, 2022 2:40 am

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Mon Mar 28, 2022 2:40 am linkquote
Thanks.
That's what it looked like from what I could see. From manual (2011, bike is 2013) it looked like whole crankcase needs replacement as previous post said.
SaFiS wrote:
Replace your final drive cover (OEM code: 8320525) and you'll be fine…
Wed Apr 06, 2022 12:10 pm

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Wed Apr 06, 2022 12:10 pm linkquote
Ordered a new cover for £200, arriving soon, then found an arm casing on eBay which I bought for £50.

I swapped the variator weights, can't wait to try, a simple job taking minutes if using an impact wrench to loosen nuts instead of cracking casing with a normal wrench.

I would strongly recommend resisting the temptation to run the engine out of idle curiosity before torquing the variator nut, particularly in a crowded yard as it gets dark - the outer variator half can travel a long way when it departs.

Just need to swap cover in the light. Meanwhile here's the bit of aluminum casting that takes all the stress when you use the rear brakes.



Wed Apr 06, 2022 2:28 pm

Veni, Vidi, Posti
2008 MP3 500, 2013 BV350, 2020 Vespa Sei Giorni
Joined: 13 Oct 2012
Posts: 8765
Location: Ashburn, Va. Home to the Internet
 
Veni, Vidi, Posti
2008 MP3 500, 2013 BV350, 2020 Vespa Sei Giorni
Joined: 13 Oct 2012
Posts: 8765
Location: Ashburn, Va. Home to the Internet
Wed Apr 06, 2022 2:28 pm linkquote
In the future, use a piece of velcro or a bungy cord wrapped around the rear brake lever to hold the rear wheel.
Wed Apr 06, 2022 9:09 pm

Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 22098
Location: Harriman, Tennessee, Tn
 
Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 22098
Location: Harriman, Tennessee, Tn
Wed Apr 06, 2022 9:09 pm linkquote
WEB-Tech wrote:
In the future, use a piece of velcro or a bungy cord wrapped around the rear brake lever to hold the rear wheel.
zip tie
Thu Apr 07, 2022 4:36 pm

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Thu Apr 07, 2022 4:36 pm linkquote
WEB-Tech wrote:
In the future, use a piece of velcro or a bungy cord wrapped around the rear brake lever to hold the rear wheel.
In fact you don't even need to do that if you use an impact wrench. I was going to but some post said don't, use a breaker bar. Garage I spoke to said he always used one. Even not having a rear brake the clutch nut came off with impact wrench as inertia of rear drive was enough in itself.
Thu Apr 07, 2022 4:37 pm

Molto Verboso
2019 Supertech (EURO3/APAC)
Joined: 17 Nov 2020
Posts: 1859
Location: Batmania aka Melbourne, Australia
 
Molto Verboso
2019 Supertech (EURO3/APAC)
Joined: 17 Nov 2020
Posts: 1859
Location: Batmania aka Melbourne, Australia
Thu Apr 07, 2022 4:37 pm linkquote
Ilya wrote:
In fact you don't even need to do that if you use an impact wrench. I was going to but some post said don't, use a breaker bar. Garage I spoke to said he always used one. Even not having a rear brake the clutch nut came off with impact wrench as inertia of rear drive was enough in itself.
yeah but when doing it up again and you want to torque it correctly ...
Thu Apr 07, 2022 11:37 pm

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Thu Apr 07, 2022 11:37 pm linkquote
Yup, will do just that (still waiting for part to finish). You prompted me to re-check the torques. Thanks. Had mis-recalled and done big nut to 80 rather than 160 and was going to do rear to 60 rather than 95 so saved me possible embarrassment!
steelbytes wrote:
yeah but when doing it up again and you want to torque it correctly ...


Last edited by Ilya on Fri Apr 08, 2022 10:47 pm; edited 1 time in total
Fri Apr 08, 2022 11:55 am

Hooked
2008 fuoco
Joined: 19 Jul 2015
Posts: 434
Location: United Kingdom.
 
Hooked
2008 fuoco
Joined: 19 Jul 2015
Posts: 434
Location: United Kingdom.
Fri Apr 08, 2022 11:55 am linkquote
And don't get mixed up with ft-lbs and nm's easy done sometimes.
Fri Apr 08, 2022 2:30 pm

Molto Verboso
2019 Supertech (EURO3/APAC)
Joined: 17 Nov 2020
Posts: 1859
Location: Batmania aka Melbourne, Australia
 
Molto Verboso
2019 Supertech (EURO3/APAC)
Joined: 17 Nov 2020
Posts: 1859
Location: Batmania aka Melbourne, Australia
Fri Apr 08, 2022 2:30 pm linkquote
3legsofman wrote:
And don't get mixed up with ft-lbs and nm's easy done sometimes.
this is why I wish Robot would stop saying ftlbs in his videos.
Fri Apr 08, 2022 11:13 pm

Hooked
2008 fuoco
Joined: 19 Jul 2015
Posts: 434
Location: United Kingdom.
 
Hooked
2008 fuoco
Joined: 19 Jul 2015
Posts: 434
Location: United Kingdom.
Fri Apr 08, 2022 11:13 pm linkquote
It dosen't help when your torque wrench has dual readings and your more used to ftlbs.i'll get used to newton metres just like i have got used to,well almost to the metric system . It's a bit easier than using BSF,whitworth,cycle in all it's different tpi's,BA, unc,unf bsp&t,ME and lots of odd ball specials that turn up sometimes.
Sat Apr 09, 2022 7:35 am

Veni, Vidi, Posti
2008 MP3 500, 2013 BV350, 2020 Vespa Sei Giorni
Joined: 13 Oct 2012
Posts: 8765
Location: Ashburn, Va. Home to the Internet
 
Veni, Vidi, Posti
2008 MP3 500, 2013 BV350, 2020 Vespa Sei Giorni
Joined: 13 Oct 2012
Posts: 8765
Location: Ashburn, Va. Home to the Internet
Sat Apr 09, 2022 7:35 am linkquote
steelbytes wrote:
this is why I wish Robot would stop saying ftlbs in his videos.
You should always consult the shop manual and not take somebody word in a video. Robot has made mistakes multiple times, and corrected later in the video. If youu don't watch the whole video you may not catch the correction, always check the shop manual unless you know what the torque is supposed to be.
Sun Apr 17, 2022 2:05 am

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Sun Apr 17, 2022 2:05 am linkquote
So, almost feeling quite pleased with myself, replaced transmission cover, replaced badly scored brake disc, put on new tyre, torqued correctly, loctite, and then discovered this…


Bonus component. Think it goes between brake hub and transmission cover.

Sun Apr 17, 2022 2:12 am

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Sun Apr 17, 2022 2:12 am linkquote
For those interested, here is inside of transmission. And how badly scored a disc can get.


Old v new discs


New transmission cover


Cracked brake mountings


Inside final drive

Sun Apr 17, 2022 2:19 am

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Sun Apr 17, 2022 2:19 am linkquote
Looks like it goes between wheel and swing arm, that's a lot less hassle, apart from that bloody split pin.



Sun Apr 17, 2022 6:48 am

Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 22098
Location: Harriman, Tennessee, Tn
 
Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 22098
Location: Harriman, Tennessee, Tn
Sun Apr 17, 2022 6:48 am linkquote
Ilya wrote:
So, almost feeling quite pleased with myself, replaced transmission cover, replaced badly scored brake disc, put on new tyre, torqued correctly, loctite, and then discovered this…
LOCKTITE why ? where? NO locktite, no locktite.
Sun Apr 17, 2022 9:16 am

Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
 
Enthusiast
MP3 500Ie LT sport 2013
Joined: 23 Feb 2022
Posts: 50
Location: Kent UK
Sun Apr 17, 2022 9:16 am linkquote
old as dirt wrote:
LOCKTITE why ? where? NO locktite, no locktite.
On the little bolts holding the brake disc on.



Sun Apr 17, 2022 2:36 pm

Addicted
2012 Genuine Stella 150 4T "Penultimate"
Joined: 15 Jan 2019
Posts: 880
Location: Texas
 
Addicted
2012 Genuine Stella 150 4T "Penultimate"
Joined: 15 Jan 2019
Posts: 880
Location: Texas
Sun Apr 17, 2022 2:36 pm linkquote
Ilya wrote:
Looks like it goes between wheel and swing arm, that's a lot less hassle, apart from that bloody split pin.
Many of us have been where you are. Nothing like finishing a job with parts left over.

At least you caught it before you tried to ride it.

Good luck.
Thu Apr 21, 2022 7:53 pm

Hooked
50cc Beo, BigBeo 2003
Joined: 30 May 2015
Posts: 438
Location: Chelyabinsk, Russia
 
Hooked
50cc Beo, BigBeo 2003
Joined: 30 May 2015
Posts: 438
Location: Chelyabinsk, Russia
Thu Apr 21, 2022 7:53 pm linkquote
Ilya wrote:
On the little bolts holding the brake disc on.
Ah, no problem, you do not need to dismount it from the wheel.
Fri Apr 22, 2022 3:44 pm

Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 22098
Location: Harriman, Tennessee, Tn
 
Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 22098
Location: Harriman, Tennessee, Tn
Fri Apr 22, 2022 3:44 pm linkquote
Ilya wrote:
On the little bolts holding the brake disc on.
ok ok I imagined you locktighting all the bolts on the cover and everything
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