Another transmission thread - but different symptoms than most - Page 3 - ZX6R Forum
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post #31 of 51 Old 10-22-2016, 07:43 AM Thread Starter
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Ooooh! And after the beer has worn off this morning, a closer inspection of the drum shows some wear in the right hand most fork guide.

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post #32 of 51 Old 10-22-2016, 09:20 AM
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Time to split the cases!
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post #33 of 51 Old 10-22-2016, 02:32 PM Thread Starter
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Time to split the cases!

My guess is, that'll be the final verdict on this one. I'm gonna go ahead and see how she acts, buttoned up with a new bottom end. If the symptoms don't change, then we can probably surmise that it's worn dogs up top. But, if she's good to go with a new bottom end and star, sheeeeeeeeeeeeet man, might just rock it like that until the inevitable, maybe.

Doing this for science.
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post #34 of 51 Old 10-24-2016, 11:04 AM
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Great pics and write up. Let us know how she turns out once you get the parts and her back together.
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post #35 of 51 Old 10-26-2016, 07:59 AM Thread Starter
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Great pics and write up. Let us know how she turns out once you get the parts and her back together.
Thanks, I can't take much credit. I'm really just following the awesome step by step procedure that was posted in a different forum.

I'm waiting for parts, and found a online retailer that was way cheaper than the real big OEM parts houses.

Got all shift forks for a total of 153+shipping, but oddly enough, I wasn't able to order the drum from them online. Turns out they do carry it, It's just not listed on their website to purchase. So, since I got itchy and didn't want to wait until Tuesday to talk to them, I ordered the drum assembly from another place, and it's coming with a new OEM star assembly, which I won't need since I also purchased the Factory Pro Evo shift star kit (SHFT-EVO-K37)

Hope to have it all this weekend. *fingers crossed*

Total out of pocket for far:

Forks - 172.28
Factory Pro Evo Star kit w/gasket - 149.00
Drum assembly - $125
Oil pan gasket - $13

So, about $450 in parts. If nothing is needed on the top half, not bad at all. If 3rd gear is still roasted, then I'll just drop in a new tranny and call it a day. Then, the thing should be pretty solid for the length of my ownership.

Will update
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post #36 of 51 Old 10-26-2016, 12:29 PM
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Originally Posted by KawiSockIt View Post
Thanks, I can't take much credit. I'm really just following the awesome step by step procedure that was posted in a different forum.

I'm waiting for parts, and found a online retailer that was way cheaper than the real big OEM parts houses.

Got all shift forks for a total of 153+shipping, but oddly enough, I wasn't able to order the drum from them online. Turns out they do carry it, It's just not listed on their website to purchase. So, since I got itchy and didn't want to wait until Tuesday to talk to them, I ordered the drum assembly from another place, and it's coming with a new OEM star assembly, which I won't need since I also purchased the Factory Pro Evo shift star kit (SHFT-EVO-K37)

Hope to have it all this weekend. *fingers crossed*

Total out of pocket for far:

Forks - 172.28
Factory Pro Evo Star kit w/gasket - 149.00
Drum assembly - $125
Oil pan gasket - $13

So, about $450 in parts. If nothing is needed on the top half, not bad at all. If 3rd gear is still roasted, then I'll just drop in a new tranny and call it a day. Then, the thing should be pretty solid for the length of my ownership.

Will update
Can you please share this online retailer's information?

I have a couple things I need to order, and I would like to see if they carry them and what their prices are.

Thanks!

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post #37 of 51 Old 10-26-2016, 12:55 PM
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1. If you need a transmission set I have two in the classified section....

2. With the drum out you should be able to inspect the dogs for rounding

Ive spit the cases on my race bike a few times myself
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post #38 of 51 Old 10-26-2016, 02:48 PM Thread Starter
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Can you please share this online retailer's information?

I have a couple things I need to order, and I would like to see if they carry them and what their prices are.

Thanks!

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1. If you need a transmission set I have two in the classified section....

2. With the drum out you should be able to inspect the dogs for rounding

Ive spit the cases on my race bike a few times myself
I'll be sure to ping you if it comes to that.

I can see up into the gear dogs that are facing down. To me, looks good enough for me to button and back up and give it a shot, that's for sure. If I'm being honest, since I don't have a set of new gears right beside me, and having no history of ever doing this before, I don't really have a barometer for them.

My thinking is, if it takes me 1/2 a day to get it all buttoned up once I get all my parts, I'll know pretty immediately if 3rd gear is roasted or not. If it is, the engine needs to come out anyway, so all I lose if 1/2 a day of putting it back together. I can live with that.

But, maybe we get lucky and she's good to go with a new bottom end.
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post #39 of 51 Old 10-27-2016, 06:08 AM
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I can see up into the gear dogs that are facing down. To me, looks good enough for me to button and back up and give it a shot, that's for sure. If I'm being honest, since I don't have a set of new gears right beside me, and having no history of ever doing this before, I don't really have a barometer for them.
Huh barometer? Visual inspection is all you need

This is an example of a worn / bad dog...

Link with pics to mine of a good set... Link
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Last edited by MFChop; 10-27-2016 at 06:14 AM.
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post #40 of 51 Old 10-27-2016, 07:50 AM Thread Starter
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Barometer, meaning a new set of gears to compare the current ones with, to see the difference.



Remember, my gears are still up in the bike... I'm doing all my work, on my back, lookup up into bottom of the engine. I won't be able to get eyes on them out of case, unless I pull the engine, of course.


Thanks for the link and pic... I'll circle back to you if it turns out I need to purchase a tranny. <------- Wait, that sounded bad.

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post #41 of 51 Old 11-02-2016, 09:08 AM Thread Starter
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Another transmission thread - but different symptoms than most

Finally got all the parts in. I won't bother showing pics of the new shifter forks and drum, but here's what the new aftermarket shift star (left) and stronger spring looks like, beside the OEM one, if anyone cares.

This shows why it's not going to take much effort to get this thing to swap cogs into a different gear. Interested to see how this translates into real-world street riding.

Assembly tonight, hopefully.






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Last edited by KawiSockIt; 11-02-2016 at 09:16 AM.
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post #42 of 51 Old 11-02-2016, 04:21 PM Thread Starter
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Another transmission thread - but different symptoms than most

Well, I'll be god damned!!! Just got back from a test ride, and guess what? The summa bitch runs perfectly. Truth be told, I didn't really get on it too much, since it was the maiden voyage, plus its dark out. But I ran through all 6 gears, and no slipping, it didn't catch on fire, nor did it spontaneously combust. So it's early going, but I'm calling this a win.





Scary moment of the evening: I refilled the crankcase and went ahead and changed the filter of course, and when I fired it up, the oil level in the sight glass didn't move!!! I had a sick feeling in my stomach, and I started running everything back through my head about what I possibly could've screwed up. Turns out, I just had to burp the oil system and everything was fine. But good lord, I did not like that one bit.





Once my stomach settled, I went for about a 5 mile ride, and now it's back in the garage. I'll check for oil leaks in the morning. The next time I go out riding, I'll take this bike instead of the Daytona and really put it through it's paces before I'll 100% confirm I'm in the clear.



Time to crack a beer.
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Last edited by KawiSockIt; 11-02-2016 at 06:25 PM.
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post #43 of 51 Old 11-06-2016, 05:43 PM
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Right on!!! Looking forward to seeing how you like the new shift star as I was thinking about putting one in. Nice work
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post #44 of 51 Old 11-06-2016, 05:54 PM
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Quote:
Originally Posted by KawiSockIt View Post
Finally got all the parts in. I won't bother showing pics of the new shifter forks and drum, but here's what the new aftermarket shift star (left) and stronger spring looks like, beside the OEM one, if anyone cares.

This shows why it's not going to take much effort to get this thing to swap cogs into a different gear. Interested to see how this translates into real-world street riding.

Assembly tonight, hopefully.






Sent from my iPhone using Tapatalk
This is one of the mods I intend to do in the next month. It's supposed to be straightforward job.
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post #45 of 51 Old 11-07-2016, 02:01 PM Thread Starter
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Originally Posted by upland117 View Post
Right on!!! Looking forward to seeing how you like the new shift star as I was thinking about putting one in. Nice work


Maybe it's just the recency effect, but I don't know how I ever rode without one. In my opinion, you mostly notice it on the 1-2 shift, as it makes neutral seem nearly imperceptible. Still getting used to it during very spirited riding, as I don't do a whole lot of that on the street. But, I have found a couple time to have shifted quicker than I could even get the clutch pulled in time. It's just slight nudge of your toe and BOOM, it's in the next gear without hesitation. I suppose those who do a lot of track or spirited riding will benefit from it most. For me, I like the 1-2 shift, as it feels like every other upshift. Finding neutral isn't a problem on this bike, as we know, since it has that positive neutral finder at stop.




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