05-06 ZX6R/RR Change out shifting forks - Page 12 - KawiForums - Kawasaki Motorcycle Forums
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post #111 of 117 (permalink) Old 09-22-2016, 10:54 AM
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I'm gonna say on that year you won't have to split the engine, but lay it on it's side and pop the clutch out to get to everything. It will be a major PITA, but then it's all about the $$.
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post #112 of 117 (permalink) Old 09-23-2016, 02:44 AM
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thank you for answer , i wish dogs will be ok .... will do this job in few weeks , or days . will write about it . it's just pop out in second some times , in neutral . that's it , on trackday it's ok , maybe because in racing gear shifting is more agressive . even if dogs will have some wear on it , is it possible to change just forks and drum , for solve this problem ????
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post #113 of 117 (permalink) Old 09-23-2016, 05:31 PM
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One thing I have done to my bikes is flip the shifter to "GP" shifting. 1 up 5 down. I would hold my foot on the shifter for 2nd and 3rd gears. It was too late, the damage was done, but the few more times out on the track and street, it did help. My ZRX problem "WAS" caused because the shifter wasn't sticky from chain lube. Beat it up at Barber one year and found out that was the cause, not the gear box. Hard lesson learned on 2 bikes. I did buy the Star Shift Kit for both bikes when I repaired them. When you replace the drum and forks, take a picture in there if you can because I think I mentioned in post earlier, I think it's the middle fork, you can put it wrong and you won't be able to shift at all. Don't feel bad, I have to pop the head off my Camry again.....another burnt valve!!!!
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post #114 of 117 (permalink) Old 09-25-2016, 11:22 AM
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ok , thank you very much. yes i read all this theme here , and i will mark fork with something to put it right way . hope it will works good , because i don;t want to split engine .will see what damage will be inside .
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post #115 of 117 (permalink) Old 10-17-2016, 05:34 PM
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All, hello.


I'm on my second 2006 636, sold the first one for no good reason, other than to buy a Daytona 675 for the most part. My wife was going to keep the first one, but decided it was too much bike, so I sold it. Then I realized that I should always have a 636 in the garage, just because of the sheer comfort of it. It's literally the most comfy sport bike I've ever owned....then sold....then owned again, but I digress..


Bought this one, at a steep discount, because of an intermittent gear issue. Let's play...

Gears 1,2,3,4,5, and 6 all engage smoothly upshifting and also, with a throttle blip doing back down.

Gears 1,2,3,4,5, and 6 all stay engaged when the bike is ridden spiritedly.

However, gear number 3 and only 3, will slip when applying light throttle. "Cruising" amount of throttle, if you will. If accelerating briskly in 3rd, or blipping back down into 3rd, everything seems fine.

First thought is clutch. That's what it feels like when you intentionally slip the clutch, but only in 3rd gear? Nah, probably not right? So, using my mad googling and forum search skills, we're probably looking it shift fork(s), drum and/or gears, yes? Correct me if wrong, but if it were a fork or drum, it'd have a hard time going into gear, correct? And if it were worn dogs on the gear, it'd come out (slip) under hard or brisk throttle, but more likely to stay engaged during light throttle, yes?

Is my logic flawed? Obviously, the pan has to come off and first step is to inspect as much as I can without removing the engine, but I though I'd ping the braintrust here first. Seems like the majority of trans problems are the 2nd gear false neutral or 2/3 gear problems under hard acceleration. My issue the exact opposite..

Thoughts?
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post #116 of 117 (permalink) Old 10-20-2016, 09:17 AM
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so , here is what i see , after chopeed my oil pan and clutch basket . what do you think ? i think it's worn hard ...also have inspect worn by manual and everything it's in change condition . have already order drum and 3 forks . on gears there is no problem i think . i can't turn it to see every of tooth , but seems that they are cool . hope i will works fine after i change this parts , that i order .
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post #117 of 117 (permalink) Old 05-10-2018, 04:14 PM
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Will this be the same procedure for a 2000-2002 zx6r?
All the same without cracking the case like you did here?
Having problems with mine too so I need to bump this lost hhaha
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