Gearbox Selector Drum Pin Failure

5041 Views 14 Replies 9 Participants Last post by Randomtone, 2 mo ago

AshG

Discussion Starter · Apr 15, 2017

hey guys i dont oftem post on here as im usually out enjoying my scrambler.

a few week back i was riding home from work and i lost 5 & 6th gear on the bike. got it home and thought i will look at it another day as the weather turned for the worse. called the dealer to have a look at it and they couldnt fit me in for 2 weeks, so i thought what the heck i will take off the alternator cover and have a look and see if the selector arm had come loose (common problem on monsters).

well i got the cover off an the selector was fine but the selector drum wasn't. the pin for 5th gear has fallen out! fortunately i found the pin and clip thats supposed to retain it floating around in the bottom of the casing.

now the problem! i cant see any way of reinserting the pin and getting the retaining clip back onto the back of the pin with out removing the engine and splitting the casing. if anyone knows how to get it back in without stripping the whole engine i would be eternally grateful.

To say I'm upset that this has happened on a year old bike with only 4000 miles on it is understatement of the year.

now the question is do it just put it back together and take it to the dealer and have them strip it down and fix it or just sort it out myself. I have spent my whole life fixing crummy old bikes/cars and finally managed to save up and buy a brand new one expecting not to have to deal with this kinda stupid stuff!

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Hui

· #2 · Apr 15, 2017

A year old bike still has one year left under warranty. If you phone it in as a breakdown the dealer should give it priority and certainly not two weeks wait just to look at it.
Are there any other dealers near you ? I have only one dealer in the whole country (Scotland) and they are four hour away.

greer

· #3 · Apr 15, 2017

I was going to ask about the warranty, too. Where are you, Ash?

Sarah

AshG

Discussion Starter · #4 · Apr 16, 2017

I'm in Atlanta GA. There are two dealers here the one i got the bike from..... Well i wouldn't even let them service it after the last experience, there is no way I'm gonna let them tare down my engine. I spoke with the other dealer in Marietta and they said they will do it but they cant fit me in for a couple of weeks as they are really busy.

I think i may have found a way to fix it without stripping the whole engine. If remove the back wheel i can remove the neutral bearing and spring. with that out i can see the back of the selector tube and more importantly i can see the other clips that are still in place. If I'm super careful i may be able to get the clip down through the hole and back on with a pair of thin medical forceps, the challenge will be not to drop the clip down into the engine.

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DouglasLee

· #5 · Apr 16, 2017

Wow, hope thats a one off situation. Probably a good idea to have the parts department order a new pin and clip? The pair in your hand obviously not playing well together. Alternatively your local auto parts or machine shops might have a “better" style snap ring which would be easier to install in a tight location using external snap ring pliers. They are available with different style tips, straight, 90, 45, etc. From the photo I am not seeing how it would be possible to snap the clip back into place without some major disassembly. If you have any doubt probably better to hang up your helmet for a couple weeks rather than risk dropping something into the nether regions of the engine case. In mean time tell them to order new parts.

AshG

Discussion Starter · #6 · Apr 17, 2017

well its took me all day to fix it but i have managed to do it and not have to take the whole engine apart!. i think the original clip must have not been pressed all the way home when the selector barrel was assembled at the factory. I scoured the internet trying to find another person with a Ducati that had the same problem to no avail so i guess its not a common problem.

Anyway here is how it fixed it... fortunately i have a full machine shop in my basement so i figured if i could machine a collet style snap ring i could feed it into the hole then follow it in with the pin with a dab of grease to keep them together while i pressed it home. Fortunatly at the end of the hole there was solid metal so i had something to press against so i could press on the pin and and get the collet to engage so it locked in place.

It was somewhat nerve racking. i knew if i dint use the correct amount of force and a smooth swift motion the collet would drop down into the engine. i stopped had a cuppa tea (am a Brit after all) then went for it. hey presto success pin went in collet snapped in place back in business!

Just waiting for the sealant on the alternator cover to dry then i can put some oil in and take her out for a test ride tomorrow after work.

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Reactions: 5

pfmtrumpy

· #7 · Apr 17, 2017

Well done. Ever considered emigration to Australia? You'd love SE QLD. ...just bring your basement.

Reactions: 1

Armo

· #8 · Apr 17, 2017

If I had a medal I'd send it to you! Well done.

greer

· #9 · Apr 17, 2017

What Armo said, outstanding! Hope it buttons up good as new.

Sarah

Reactions: 1

AshG

Discussion Starter · #10 · Apr 18, 2017

its all back together took it out for a quick test run last night then rode into work today, gearbox feels better than it ever has!

will have to put some pictures up of the bike soon. i have done quite a few upgrades to it so far with more planned.

Adriani front fork inserts, ohlins rear suspension, hydraulic clutch conversion, termi race exhaust, rexxer remap, dart fly screen, most panels and mud guards replaced with carbon fiber.

Jackson

· #11 · Apr 20, 2017

Well done, maybe clue was always there but very big win from potential catastrophe, could've been carnage in there, very big skid if lock up happened in 6th
Top work, bet the rest of bike is lovely too but why drybollock clutch ? I've only ever had grief from them, cable doesn't give any

AshG

Discussion Starter · #12 · Apr 20, 2017

i didn't like the feel of the cable clutch, i have rode a monster in the past, the feel and weight of the hydraulic clutch was far superior. I agree they can be a little more troublesome if not maintained but i felt it was worth the risk for improved rideability. The latest design from Ducati is actually far superior to the older design where the push rod could spin the slave cylinder and destroy it which is why i wasn't so worried about changing to hydraulic.

i can say after doing the conversion it certainly helped with the low speed cornering/traffic and low end snatchy throttle, as it improves the feed in modulation of the clutch.

the conversion wasn't too bad to do as you can just order all the parts from a 2012 796 monster.

you will need

clutch lever/master cylinder
hydraulic hose
slave cylinder
push rod (comes with seals and anti spin pin)
clutch control pin
clutch control pin bearing (you can reuse your old bearing but if you don't have a good vice or a press you will destroy it in the removal/ control pin swap process).

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AshG

Discussion Starter · #13 · Apr 20, 2017

Automotive lighting Auto part Diagram Automotive exterior Line art

here is a picture of the bits you need to acquire from the 2012 monster.

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l8rg8r

· #14 · Jan 15, 2022

AshG said:
well its took me all day to fix it but i have managed to do it and not have to take the whole engine apart!. i think the original clip must have not been pressed all the way home when the selector barrel was assembled at the factory. I scoured the internet trying to find another person with a Ducati that had the same problem to no avail so i guess its not a common problem.

Anyway here is how it fixed it... fortunately i have a full machine shop in my basement so i figured if i could machine a collet style snap ring i could feed it into the hole then follow it in with the pin with a dab of grease to keep them together while i pressed it home. Fortunatly at the end of the hole there was solid metal so i had something to press against so i could press on the pin and and get the collet to engage so it locked in place.

It was somewhat nerve racking. i knew if i dint use the correct amount of force and a smooth swift motion the collet would drop down into the engine. i stopped had a cuppa tea (am a Brit after all) then went for it. hey presto success pin went in collet snapped in place back in business!

Just waiting for the sealant on the alternator cover to dry then i can put some oil in and take her out for a test ride tomorrow after work.

AshG said:
hey guys i dont oftem post on here as im usually out enjoying my scrambler.

a few week back i was riding home from work and i lost 5 & 6th gear on the bike. got it home and thought i will look at it another day as the weather turned for the worse. called the dealer to have a look at it and they couldnt fit me in for 2 weeks, so i thought what the heck i will take off the alternator cover and have a look and see if the selector arm had come loose (common problem on monsters).

well i got the cover off an the selector was fine but the selector drum wasn't. the pin for 5th gear has fallen out! fortunately i found the pin and clip thats supposed to retain it floating around in the bottom of the casing.

now the problem! i cant see any way of reinserting the pin and getting the retaining clip back onto the back of the pin with out removing the engine and splitting the casing. if anyone knows how to get it back in without stripping the whole engine i would be eternally grateful.

To say I'm upset that this has happened on a year old bike with only 4000 miles on it is understatement of the year.

now the question is do it just put it back together and take it to the dealer and have them strip it down and fix it or just sort it out myself. I have spent my whole life fixing crummy old bikes/cars and finally managed to save up and buy a brand new one expecting not to have to deal with this kinda stupid stuff!

Hi there @AshG - I’ve drawn the short straw and experienced the dreaded drum pin failure at 3k miles ☹☹☹

Thank you for posting about your experience and your creative fix!

Not sure I have the stomach for risking your solution!

ride safe!

Randomtone

· #15 · 2 mo ago

AshG said:
I'm in Atlanta GA. There are two dealers here the one i got the bike from..... Well i wouldn't even let them service it after the last experience, there is no way I'm gonna let them tare down my engine. I spoke with the other dealer in Marietta and they said they will do it but they cant fit me in for a couple of weeks as they are really busy.

I know this an old thread but I hope you know about Ducshop also in Marietta, they have been great to me.

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