Shift forks? Or Drum? Or... worse? - ZX6R Forum
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post #1 of 8 Old 02-27-2017, 02:29 PM Thread Starter
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Shift forks? Or Drum? Or... worse?

Hey all,

So I've searched and found good info - I know how to do most things regarding the swap (in theory) but wanted more input cause my issue is kinda' slightly different here.

So pulling the engine isn't an option here. I can't split the case myself as I have no tools to do the full job and no room.

Over a year ago the bike fell pretty hard onto its left side, cracking the stator cover and potentially causing this mishap - because I got hit by a car and have since replaced the cover leaking oil, and fixed my problem except this.

Okay so the problem:

My first gear slips out of first into neutral. This will happen when I give it too much gas (above 8-9k RPM) and or I am downshifting coming to a stop, I hit 1st gear, and then it'll just pop out into neutral as if I didn't slam hard enough (I do lol...). NO OTHER GEAR DOES THIS. 2nd - 6th are FINE.

I mitigate this issue by holding my foot down onto the gear shift lever, and sometimes I can feel that it doesn't shift into first all the way (level is still loose as opposed to a solid feeling when you hit first and can't kick down anymore). So I kick down usually multiple times, and hold my foot on it. Been doing this for over a year now.

I don't have the cash to pay a mechanic to fix it, since it'll easily be $1k+ in repairs and I know how to switch the shift forks from a DIY here. Not afraid of that. Just got a question on what the hell that vice grip looking tool is in this thread: 05-06 ZX6R/RR Change out shifting forks - KawiForums - Kawasaki Motorcycle Forums

Anywho - what do you guys think it is from my symptoms? Worn shift fork not staying in gear under heavy torque? Dogs? Drums? If it's the last two and I gotta' split the case, I'm just gonna' sell the bike for $1000 and down pay to a new zx6. I really don't wanna' get rid of my bike, and I don't think anyone would buy it like this anyway.

Also - I have 28k miles on it. I've put about 20k on her, never abused or stunted.
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post #2 of 8 Old 02-27-2017, 04:27 PM
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Have u tried adjusting your shifter linkage? It might have gotten bent.
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post #3 of 8 Old 02-27-2017, 07:27 PM
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One thing is for sure if the forks aren't damaged now they will be if you keep mashing down on the shifter with your foot to hold it in gear. Too bad you don't have the cassette style transmission as that's a piece of cake to pull out and replace gears/forks/etc. Had to do it on one of my ZX10Rs a couple of times now. Was '07 the first year with the cassette in the ZX6R?

.
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post #4 of 8 Old 02-27-2017, 09:35 PM
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Yup, cassette type started in 07
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post #5 of 8 Old 03-01-2017, 09:39 PM
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Quote:
Originally Posted by zeroviral View Post
Just got a question on what the hell that vice grip looking tool is in this thread: 05-06 ZX6R/RR Change out shifting forks - KawiForums - Kawasaki Motorcycle Forums
That is a clutch holder tool. You will need one in order to remove bolt that holds the clutch basket.

Also, as stated by Scorpi0 above, the shift arm and/or linkage may just need to be adjusted in order to resolve the issue.

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post #6 of 8 Old 03-02-2017, 06:58 AM
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Regarding clutch holding tool, I find this one far superior:



https://www.denniskirk.com/283232.sk...ad=45713339557
Strider and eulark like this.

.

Last edited by trackdayhero; 03-02-2017 at 07:00 AM.
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post #7 of 8 Old 03-02-2017, 07:19 AM
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If you decide to sell it I'm just a few hours away and would be interested. Can't help ya with fixing it though, good luck man.
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post #8 of 8 Old 03-02-2017, 09:20 AM
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I thought the drum can be swapped without splitting the case on this bike? I could have sworn it was only the gears themselves that would require a split.

-------------
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