05-06 ZX6R/RR Change out shifting forks - Page 2 - KawiForums - Kawasaki Motorcycle Forums
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post #11 of 117 (permalink) Old 08-10-2008, 01:33 PM
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Very nice write up Spooner427. Thank you for taking the time do take the pics along the way,although I hope that I don't need to replace the shift forks any time soon in my RR.
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post #12 of 117 (permalink) Old 08-10-2008, 02:05 PM Thread Starter
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Quote:
Originally Posted by PGTS1993 View Post
What do you mean by the dogs for the gears? so if i do have to change gears out do i have to take the engine apart to get case out? i know the engine and trany have to come out but when iam looking at the case it looks like i have to take the engine apart!

I am pretty sure I am using the correct terms but the gears have teeth and dogs. The teeth are like the normal teeth on a sprocket but the dogs extend off the side of the gear and interlock 2 gears on the same shaft together. If you have to change gears you will need to pull the whole motor out of the bike. Flip the motor over and split the case. It is alot of work. I did it last year in this bike during the winter.

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Thanks for the props
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post #13 of 117 (permalink) Old 08-10-2008, 05:19 PM
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Ok! thank you u have been alot of help
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post #14 of 117 (permalink) Old 08-10-2008, 09:06 PM Thread Starter
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n/p
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post #15 of 117 (permalink) Old 08-19-2008, 08:06 PM
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Thanks for the help. I'm gonna start getting the bike prepped for it.

This sucks b/c I don't know if my second gear needs to be replaced and I'd much rather just check out the forks and drum and replace them if needed

"Ridden more aggressively, the original ZX-10R is so fcuking mad it makes Hollywood hell-raiser Russell Crowe look like a tea-drinking nancy boy." -Chris Moss
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post #16 of 117 (permalink) Old 08-19-2008, 08:40 PM
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reps for the good write up.

my forks looked about like that too.

the dogs were good tho?
might had just a slight bit of wear.

have u ran it since u got it together? i hope it doesnt continue to pop out of gear....due to worn dogs.

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post #17 of 117 (permalink) Old 08-19-2008, 10:19 PM
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I decided I'm gonna do the whole kit and kibbootle. A bud of mine is gonna help walk me through most of it but I'm gonna drop the motor and all. Wish me luck.

So far tonight I've taken off the headers and back, drained oil, drained radiator and disconnected all the rad. hoses. . .

"Ridden more aggressively, the original ZX-10R is so fcuking mad it makes Hollywood hell-raiser Russell Crowe look like a tea-drinking nancy boy." -Chris Moss
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post #18 of 117 (permalink) Old 08-20-2008, 08:52 AM
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I don't exactly understand how the Factory pro shift star would help with reducing wear on the shift forks as so many suggest it would help prevent the whole 2nd gear tranny issues.

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2005 Titanium ZX-6R - Scorpion Slipon|PCIII|FactoryPro Shift Star|Powerbronze Rear Hugger|OES Sliders & Spools|TechSpec|HVMP|Flushmounts|ZeroGravity DB Windscreen|Grip Puppies|Jumper Mod
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post #19 of 117 (permalink) Old 08-20-2008, 12:43 PM Thread Starter
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Quote:
Originally Posted by dudewhrsmybike View Post
This sucks b/c I don't know if my second gear needs to be replaced and I'd much rather just check out the forks and drum and replace them if needed
You can check your gears when you have your forks and drum dropped out of the bottom. I think in most cases just changing the forks (and shift drum if it looks really worn) will fix most problems.

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Originally Posted by nevada View Post
have u ran it since u got it together? i hope it doesnt continue to pop out of gear....due to worn dogs.
It is fine on the street but I hit open track this Friday and then race on Sunday so that will be the deciding factor.

Quote:
Originally Posted by dudewhrsmybike View Post
I decided I'm gonna do the whole kit and kibbootle. A bud of mine is gonna help walk me through most of it but I'm gonna drop the motor and all. Wish me luck.
It's not that bad. I dropped the motor, splitt the case and changed outmy gears last winter. It seems really scary but then your like ..... that's it??
When you get down to your shift forks and pull them out mark one brake side and one shifter side for the two that are on the same rod because you are gonna have to snap some pics because I want to see how they look.

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I don't exactly understand how the Factory pro shift star would help with reducing wear on the shift forks as so many suggest it would help prevent the whole 2nd gear tranny issues.
I don't think they should be put in to fix trans issues. You should figure out what is wrong with the trans and fix the problem first. Otherwise it's still there and will show up again in the future.

**Important**
Now for the interesting part. There are 3 forks in the trans: one little one and two slightly bigger. When I looked at the new bigger two they had different numbers on the side saying they came from different modling casts. One had a 5 and one had a 6. The 6 looked perfect but the 5 had been ground down by a person to smooth the edges and fix the poor cast that came out of the mold. So I am thinking that people with trans trouble "that don't abuse their bikes" could possibly have a shift fork that a person had cleaned up and possibly took too much off one side or the other(Don't run to your dealer and state this as FACT and demand for it to be fixed). I put the crappy looking one in my high gears and the nice one in my low gears so hopefully I can tell if it causes any problems.
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post #20 of 117 (permalink) Old 08-20-2008, 10:07 PM
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where did you get the spanner wrench tool from? i need one asap
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