HELP!!! Possible Bent Countershaft?! (TT250)

PNWDualRider · 07-24-2016, 02:28 PM

Hey guys, I got home from one evening and noticed my chain was loose. I tightened it to 15mm of free play exactly, and now the chain has a grinding sound twice per rotation of the wheel. I looked all over to see where it might be grinding and I am wondering what I should do. I know I have not over tightened the chain as it clearly has 15mm maybe even 16mm of free play which the manual says is what you need. What else might be the problem?? Help please as I am leaving on an adventure ride this Thursday... Thanks in advance.

PNWDualRider · 07-24-2016, 02:47 PM

Here is a video of the sound for reference...

Azhule · 07-24-2016, 03:04 PM

Did you take the front sprocket cover off yet? Grab a Hockey Puck and a Jack, set it on the right rear area on the frame (near the rear shock usually) to raise the rear tire off the ground, this way you can spin the tire while looking at everything while it's spinning.

Also how many teeth on each sprocket and how many links in the chain?

PNWDualRider · 07-24-2016, 03:14 PM

UPDATE*** I took off the sprocket cover to see if I could see anything wobble and I shifted through some gears and it seems to have disappeared which leads me to believe it might be a transmission thing. I wonder if I broke some teeth off the sprockets in the gearbox because when accelerating from a stop, it seems like it has to grind and then catch in first gear to get going...

BlackBike · 07-24-2016, 03:22 PM

Quote:

Originally Posted by PNWDualRider

UPDATE*** I took off the sprocket cover to see if I could see anything wobble and I shifted through some gears and it seems to have disappeared which leads me to believe it might be a transmission thing. I wonder if I broke some teeth off the sprockets in the gearbox because when accelerating from a stop, it seems like it has to grind and then catch in first gear to get going...

Next, inspect the dumped oil for fod.

PNWDualRider · 07-24-2016, 03:57 PM

Quote:

Originally Posted by BlackBike

Next, inspect the dumped oil for fod.

Sounds good. I'll do a full oil change and inspect oil. Am I looking for anything in particular or just chunks of metal? Thank you all for the help so far. I'm willing to do the work if I know what I am doing. Love you guys lol

kohburn · 07-24-2016, 04:20 PM

broken gear teeth will give you chunks, instead of shavings.

PNWDualRider · 07-24-2016, 08:51 PM

UPDATE** I changed the oil and cleaned the oil screen and among the many metal shavings, there weren't any chunks. I fired up the bike and let it run a bit until it studdered then died. Would not turn over. The first thing that popped into my mind was that I didn't put enough oil or I used the wrong type. I checked the oil, 10w/40 and I put in about 1.3 quarts in. Then I laughed at myself, fuel switch was not flipped to run. Flipped it on and it runs like a dream. The oil that came out was thick black and I can't believe it was that dirty in 190km from city riding. I will take it out another day as I'm about to watch a movie with the Mrs, to do some real testing. But so far, it seems the problem has resided.

BlackBike · 07-24-2016, 10:37 PM

How bad? Get that oil and put in suspension, then pour a small amount on a white paper plates and take a pic. Some of these guru can tell if it's something serious going on inside. If your worried about you may want to contact the mothership (csc). Small amounts are normal. Here's my first from the bashan as to compare.
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2LZ · 07-25-2016, 10:36 AM

Quote:

Originally Posted by PNWDualRider

UPDATE*** I took off the sprocket cover to see if I could see anything wobble and I shifted through some gears and it seems to have disappeared which leads me to believe it might be a transmission thing. I wonder if I broke some teeth off the sprockets in the gearbox because when accelerating from a stop, it seems like it has to grind and then catch in first gear to get going...

Odds are you may have picked up something on the chain (piece of gravel, etc.) and ran it through the countershaft sprocket, would be my guess.
I'd imagine that busting a tooth off a gear is virtually impossible, especially with the mammoth HP that these put out. ;-)
Also, it's normal for the CG motor countershaft sprocket to wiggle. That's why I'm not concerned about running a flat sprocket on the rear and having the length of the chain make up the 4mm +/- offset.....or "we'll see".

Keep us posted.

PNWDualRider · 07-26-2016, 11:58 PM

Quote:

Originally Posted by BlackBike

How bad? Get that oil and put in suspension, then pour a small amount on a white paper plates and take a pic. Some of these guru can tell if it's something serious going on inside. If your worried about you may want to contact the mothership (csc). Small amounts are normal. Here's my first from the bashan as to compare.
Attachment 6823

The shavings inside my oil for like small pieces of glitter. I thought I'd tear off the sprocket cover and investigate the teeth and all looked well. I decided to tighten the 2 bolts that hold on the front sprocket to see if maybe he knocking was a loose bolt on the front sprocket and the first, perfectly tightened, the second moved freely and so I loosened softly and the bolt fell out completely stripped! I can not believe this was so stripped from the factory. It has been held on by one bolt this whole time... That could've been really bad... But I will purchase a new bolt from the hardware store possibly Thursday before my trip to see if that was the issue.

On a side note, look what else came today!

PNWDualRider · 07-27-2016, 12:00 AM

Quote:

Originally Posted by PNWDualRider

The shavings inside my oil for like small pieces of glitter. I thought I'd tear off the sprocket cover and investigate the teeth and all looked well. I decided to tighten the 2 bolts that hold on the front sprocket to see if maybe he knocking was a loose bolt on the front sprocket and the first, perfectly tightened, the second moved freely and so I loosened softly and the bolt fell out completely stripped! I can not believe this was so stripped from the factory. It has been held on by one bolt this whole time... That could've been really bad... But I will purchase a new bolt from the hardware store possibly Thursday before my trip to see if that was the issue.

On a side note, look what else came today!

Picture attached of the bolt holding on my front sprocket.

Bruce's · 07-27-2016, 12:33 AM

Purchasing a new bolt might not help much ,those buggered up threads have more than likely transferred to whatever they were threaded into .I guess it's pretty safe to say you did not remove ,locktite ,then tighten every fastener you could find while assembling your bike ?

PNWDualRider · 07-27-2016, 12:54 AM

Quote:

Originally Posted by Bruce's

Purchasing a new bolt might not help much ,those buggered up threads have more than likely transferred to whatever they were threaded into .I guess it's pretty safe to say you did not remove ,locktite ,then tighten every fastener you could find while assembling your bike ?

CSC assembled the bikes for us and they mentioned they used loctight on all the bolts. Hopefully I can replace the bolt, if not, a warranty repair will be in order as I have been obeying all of the warranty regs without a fail for the break in period. I tightened almost all the other bolts except these two... My mistake...

BlackBike · 07-27-2016, 01:29 AM

Quote:

Originally Posted by PNWDualRider

CSC assembled the bikes for us and they mentioned they used loctight on all the bolts. Hopefully I can replace the bolt, if not, a warranty repair will be in order as I have been obeying all of the warranty regs without a fail for the break in period. I tightened almost all the other bolts except these two... My mistake...

I bet if you I D the part numbers and Emil csc they would ship it to you asap. Cheap part.

07-24-2016, 02:28 PM	#1
PNWDualRider Join Date: Feb 2016 Location: Washington Posts: 87	HELP!!! Possible Bent Countershaft?! (TT250) Hey guys, I got home from one evening and noticed my chain was loose. I tightened it to 15mm of free play exactly, and now the chain has a grinding sound twice per rotation of the wheel. I looked all over to see where it might be grinding and I am wondering what I should do. I know I have not over tightened the chain as it clearly has 15mm maybe even 16mm of free play which the manual says is what you need. What else might be the problem?? Help please as I am leaving on an adventure ride this Thursday... Thanks in advance. __________________ 2016 CSC TT250 2006 Zongshen ZS200GY-2 *1973 Honda SL100
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07-24-2016, 02:47 PM	#2
PNWDualRider Join Date: Feb 2016 Location: Washington Posts: 87	Here is a video of the sound for reference... __________________ 2016 CSC TT250 2006 Zongshen ZS200GY-2 *1973 Honda SL100
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07-24-2016, 03:04 PM	#3
Azhule Join Date: Dec 2015 Location: CO Posts: 1,525	Did you take the front sprocket cover off yet? Grab a Hockey Puck and a Jack, set it on the right rear area on the frame (near the rear shock usually) to raise the rear tire off the ground, this way you can spin the tire while looking at everything while it's spinning. Also how many teeth on each sprocket and how many links in the chain? __________________ "Think as you like... but this self proclaimed Professor is always right" - Buckshot "You never know what someone is hiding beneath their smile..." - NinjaTom - R.I.P.
	0

07-24-2016, 03:14 PM	#4
PNWDualRider Join Date: Feb 2016 Location: Washington Posts: 87	UPDATE*** I took off the sprocket cover to see if I could see anything wobble and I shifted through some gears and it seems to have disappeared which leads me to believe it might be a transmission thing. I wonder if I broke some teeth off the sprockets in the gearbox because when accelerating from a stop, it seems like it has to grind and then catch in first gear to get going... __________________ 2016 CSC TT250 2006 Zongshen ZS200GY-2 *1973 Honda SL100
	0

07-24-2016, 04:20 PM	#7
kohburn Join Date: Dec 2015 Location: Coastal NC Posts: 537	broken gear teeth will give you chunks, instead of shavings. __________________ -whatever you do, just be awesome. - 2008 Kawasaki Versys - 2016 CSC TT250
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07-24-2016, 08:51 PM	#8
PNWDualRider Join Date: Feb 2016 Location: Washington Posts: 87	UPDATE** I changed the oil and cleaned the oil screen and among the many metal shavings, there weren't any chunks. I fired up the bike and let it run a bit until it studdered then died. Would not turn over. The first thing that popped into my mind was that I didn't put enough oil or I used the wrong type. I checked the oil, 10w/40 and I put in about 1.3 quarts in. Then I laughed at myself, fuel switch was not flipped to run. Flipped it on and it runs like a dream. The oil that came out was thick black and I can't believe it was that dirty in 190km from city riding. I will take it out another day as I'm about to watch a movie with the Mrs, to do some real testing. But so far, it seems the problem has resided. __________________ 2016 CSC TT250 2006 Zongshen ZS200GY-2 *1973 Honda SL100
	0

07-24-2016, 10:37 PM	#9
BlackBike Join Date: Feb 2016 Location: George West, Texas Posts: 4,097	How bad? Get that oil and put in suspension, then pour a small amount on a white paper plates and take a pic. Some of these guru can tell if it's something serious going on inside. If your worried about you may want to contact the mothership (csc). Small amounts are normal. Here's my first from the bashan as to compare. __________________ ***************************************** 2015 Bashan"Blaze" BS250GY-31 (DB-07K-250) GONE 2017 Suzuki V Strom 650 XT "We are all born ignorant, but one must work hard to remain stupid." ~Benjamin Franklin~
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07-27-2016, 12:33 AM	#13
Bruce's Join Date: Apr 2015 Location: Sudbury ,Ontario Posts: 855	Purchasing a new bolt might not help much ,those buggered up threads have more than likely transferred to whatever they were threaded into .I guess it's pretty safe to say you did not remove ,locktite ,then tighten every fastener you could find while assembling your bike ?
	0