2004 Pulsar 180DTSi gearbox cracked!

Nikhilb2008 · 4th February 2010, 00:30

I have a Pulsar 180 DTSi which I bought in September of 2004. I've been using it since then. I've covered about 30,000 kms.

About an hour ago, as I was returning from dinner, there was this sudden grrrrrr noise and the bike stopped moving. The engine was running, but no power was being transferred to the rear wheels.

I stopped and this was the sight that greeted me.

2004 Pulsar 180DTSi gearbox cracked!-image0001.jpg

2004 Pulsar 180DTSi gearbox cracked!-image0057.jpg

YouTube - Cracked gearbox of 2004 Pulsar 180 DTSi

If the video doesnt play, please open in a new window.

What is the next step? How can something like this even happen? I had got the bike serviced less than a week ago. Last Saturday(30th Jan 2010) to be exact.

black12rr · 4th February 2010, 00:42

Do no what happened .
Can you remove the chain cover above the shifter and see the front sprocket ?
And where is the top bolt for front sprocket cover ? , they missed it at the service?
The chain could have broken and it would have thrown front and damaged things .

Remove the alternator cover and the sprocket cover , things will be clear .

Nikhilb2008 · 4th February 2010, 00:50

I cant open anything now. Bike is about half a km away from home. I just parked it on the footpath and came walking.

I would like to know why this has happened. Can it be repaired easily? Within a couple of thousand bucks?

black12rr · 4th February 2010, 00:56

you cant even push the bike ? , half km, push it to your home na , why leave it on road at 12 in night ? .
You know what , police will take it to station and then they will sprinkle some blood and tomorrow they will tell this was used by a thief and there was attempt to murder and they will harass . This actually happened to one of my colleague .

Nikhilb2008 · 4th February 2010, 01:10

Cant push the bike dude.... The rear wheel is locked.

aka_iitd · 4th February 2010, 01:14

It is better if you can manage to bring it back
I think rear wheel is jammed because of chain. If possible try removing the chain and try to drag it.

Nitin · 4th February 2010, 01:26

Can you get a truck on rent from somewhere and move it back home? Might be late and no one will be around, I know. No harm trying none-the-less.Or atleast if you can move the bike and keep it in front of some store, that would help.
I think one of my friends had this problem many many years ago, on his KB100.IIRC, there was some tiny crack at one of the opening of the block, and one fine day the whole thing just cracked right open,throwing my friend on the road violently. never really found out what happened to the bike.

masterblader · 4th February 2010, 04:10

That type of damage is down to the chain snapping and rolling into towards the gearbox and crankcases. If the chain is still on the rear sprocket then the top run of the chain had picked up a large object and smashed into the gearbox. The motor effectively is now scrap metal sorry to be so blunt Nik.

Sheel · 4th February 2010, 09:52

Quote:

Originally Posted by Nitin

I think one of my friends had this problem many many years ago, on his KB100.IIRC
throwing my friend on the road violently. never really found out what happened to the bike.

Jesus Christ, imagine you are entering a corner doing approx 85-90 and the thing gives away throwing you away, i turn into a pulp

aargee · 4th February 2010, 10:11

IMO, it should be the sprocket & not the gearbox & shouldn't cost you much

Sankar · 4th February 2010, 10:15

Quote:

Originally Posted by Nikhilb2008

Cant push the bike dude.... The rear wheel is locked.

Check if the chain broke. A broken chain can break the clutch cover.
Else the rotor drum inside must've come loose, breaking it the cover.

Btw its your clutch cover that broke, hope the gearbox side inside is intact.

revtech · 4th February 2010, 10:30

as already mentioned it probably happened due to the chain snapping off and in turn cracking it.

Nikhilb2008 · 4th February 2010, 11:14

The rear wheel is locked right now. I'm taking a mechanic along with me at 3:00 and seeing what can be done.

Rahulkool · 4th February 2010, 15:06

I haven't seen anything like this before, thank god you are safe.

I guess chain must have broken ..... when did you replaced the chain-sprocket kit ??

crazy4s · 4th February 2010, 17:10

chain loosen, got double layered, stuck and rolled up over the sprocket with a great thrust. cheers that you are safe and it doesn't caused any harm to you. anyway please let me know what transpires.

cheers
sajid

4th February 2010, 00:42	#2
black12rr Senior - BHPian Join Date: Dec 2005 Location: Ridin earth now Posts: 1,280 Thanked: 349 Times	Do no what happened . Can you remove the chain cover above the shifter and see the front sprocket ? And where is the top bolt for front sprocket cover ? , they missed it at the service? The chain could have broken and it would have thrown front and damaged things . Remove the alternator cover and the sprocket cover , things will be clear . Last edited by black12rr : 4th February 2010 at 00:44.
	() Thanks

4th February 2010, 00:50	#3
Nikhilb2008 Distinguished - BHPian Join Date: Jul 2006 Location: Bangalore Posts: 5,194 Thanked: 10,178 Times	I cant open anything now. Bike is about half a km away from home. I just parked it on the footpath and came walking. I would like to know why this has happened. Can it be repaired easily? Within a couple of thousand bucks?
	() Thanks

4th February 2010, 00:56	#4
black12rr Senior - BHPian Join Date: Dec 2005 Location: Ridin earth now Posts: 1,280 Thanked: 349 Times	you cant even push the bike ? , half km, push it to your home na , why leave it on road at 12 in night ? . You know what , police will take it to station and then they will sprinkle some blood and tomorrow they will tell this was used by a thief and there was attempt to murder and they will harass . This actually happened to one of my colleague .
	() Thanks

4th February 2010, 01:10	#5
Nikhilb2008 Distinguished - BHPian Join Date: Jul 2006 Location: Bangalore Posts: 5,194 Thanked: 10,178 Times	Cant push the bike dude.... The rear wheel is locked.
	() Thanks

4th February 2010, 01:14	#6
aka_iitd BHPian Join Date: Aug 2008 Location: Bangalore Posts: 637 Thanked: 52 Times	It is better if you can manage to bring it back I think rear wheel is jammed because of chain. If possible try removing the chain and try to drag it.
	() Thanks

4th February 2010, 01:26	#7
Nitin Senior - BHPian Join Date: May 2006 Location: Houston, Texas Posts: 3,294 Thanked: 22 Times View My Garage	Can you get a truck on rent from somewhere and move it back home? Might be late and no one will be around, I know. No harm trying none-the-less.Or atleast if you can move the bike and keep it in front of some store, that would help. I think one of my friends had this problem many many years ago, on his KB100.IIRC, there was some tiny crack at one of the opening of the block, and one fine day the whole thing just cracked right open,throwing my friend on the road violently. never really found out what happened to the bike.
	() Thanks

4th February 2010, 04:10	#8
masterblader BHPian Join Date: Jan 2010 Location: London Posts: 47 Thanked: 6 Times	That type of damage is down to the chain snapping and rolling into towards the gearbox and crankcases. If the chain is still on the rear sprocket then the top run of the chain had picked up a large object and smashed into the gearbox. The motor effectively is now scrap metal sorry to be so blunt Nik.
	() Thanks

4th February 2010, 10:11	#10
aargee Senior - BHPian Join Date: Jan 2010 Location: TSTN Posts: 6,353 Thanked: 10,062 Times	IMO, it should be the sprocket & not the gearbox & shouldn't cost you much
	() Thanks

4th February 2010, 10:30	#12
revtech Senior - BHPian Join Date: Nov 2004 Location: Bombay Posts: 1,992 Thanked: 39 Times View My Garage	as already mentioned it probably happened due to the chain snapping off and in turn cracking it. Last edited by revtech : 4th February 2010 at 10:32.
	() Thanks

4th February 2010, 11:14	#13
Nikhilb2008 Distinguished - BHPian Join Date: Jul 2006 Location: Bangalore Posts: 5,194 Thanked: 10,178 Times	The rear wheel is locked right now. I'm taking a mechanic along with me at 3:00 and seeing what can be done.
	() Thanks

4th February 2010, 15:06	#14
Rahulkool Senior - BHPian Join Date: Oct 2007 Location: Chennai Posts: 1,467 Thanked: 2,126 Times View My Garage	I haven't seen anything like this before, thank god you are safe. I guess chain must have broken ..... when did you replaced the chain-sprocket kit ??
	() Thanks

4th February 2010, 17:10	#15
crazy4s BHPian Join Date: Oct 2009 Location: Meerut Posts: 61 Thanked: Once	most probable cause chain loosen, got double layered, stuck and rolled up over the sprocket with a great thrust. cheers that you are safe and it doesn't caused any harm to you. anyway please let me know what transpires. cheers sajid
	() Thanks