05-06 ZX6R/RR Change out shifting forks - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 117 (permalink) Old 08-08-2008, 02:49 PM Thread Starter
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05-06 ZX6R/RR Change out shifting forks

To do this you will NEED A SPANNER CLUTCH TOOL!!! I have tried without one and broke my clutch basket which is $300 the tool is only like $30 so buy one or borrow one. If you have been wanting to install an after market shift start now is the time. I would suggest still having a manual when doing this to reference too. I am not responsible if you pull it apart and mess up or can't put it back together..... sorry. It's really not hard to do but some people can't even change plugs so please know your own limits.


1)Pull your fairings off. For stock fairings just the sides and lower should be good.



2)Unbolt your radiator and tie it forward against your front tire so you can reach the header bolts easily and not damage your radiator.



3)Remove your headers and exhaust. You might not have to completely remove everything but you need to make sure none of it is blocking the oil pan from dropping straight down. I had to remove everything but the can under the tail.


4)Drain the oil thru the plug on the oil pan and then pull the clutch cover off of the motor and remover your clutch.



5)This next part is probebly the hardest part. You WILL NEED the clutch tool to do this. I have broken my clutch basket before and they cost $300. Once you have the tool you will need an impact or breaker bar to remove that bolt. Take your time and DO NOT round it off.



6)To be able to remove the clutch basket you have to slide out the inner ring, otherwise it will not pass part of the case on the right. To slide out the inner ring I start to thread a dry wall screw into the hole and pull it out. It might take a few tries but it should slide out pretty easy.



7)Undo your shifter linkage off of the input shaft on the shifter side of the motor. Once it is off you should be able to pull the shifter rod out from the clutch side of the motor. WIth that out of the way you can see the shifting star and the ends of the rods holding your shifting forks. There is a small metal plate that is holding in the shift star/shift drum and the shift forks rod(don't remove the 2 bolts yet). Remove the oil pan from the bottom of the engine before removing any more from this side.



8) I had to lay my bike on it's side to get pics of the transmission from under. There is another rod with gears under the shifting drum you can't see.




9)Ok now remove the 2 hex heads holding in the shift star/shift drum and the shift forks. Slide out the rods and reach under the engine,try and keep a hand under the forks because they will drop out. With the front rod 1 fork will drop and with the rear rod 2 forks will drop out. Now inspect them.



Normal wear






My quick shifter killed the fork on the left. You can see it is shaved down really bad.






Install goes pretty easy just reverse it all and follow manual for all torque specs. I don't put in new gaskets everytime because my motor is taken apart too much. I clean the old one and all surfaces and use gasket maker from the parts store. It took me about 2 hours with taking pics to drop the forks out. To change out gears you will have to remove your WHOLE motor and split your case but with the shift drum and the shift forks out you can easily inspect all your gears for damage and see if they need to be replaced.
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post #2 of 117 (permalink) Old 08-08-2008, 04:24 PM
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Great pics/write up! Thats a hell of paint job you have... How much did that cost you?
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post #3 of 117 (permalink) Old 08-08-2008, 05:50 PM
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awesome addition. next time you should do a 12oclock to get a good pic of the shift drum lol

You should also put what your symptoms were that led you to replacing the forks!

Ride hard, die free

Last edited by pyros46290; 08-09-2008 at 01:47 PM. Reason: site advancement
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post #4 of 117 (permalink) Old 08-08-2008, 05:54 PM Thread Starter
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Quote:
Originally Posted by phissure View Post
Great pics/write up! Thats a hell of paint job you have... How much did that cost you?
It was done by a friend. I paid for supplies and he threw in his time for free so it was pretty cheap.
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post #5 of 117 (permalink) Old 08-09-2008, 08:11 AM
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Shift forks looked like they did on my ZRX. Problem is they get bent and start rubbing. The bent is ever so slight, but it reaks havoc with the gears staying in place. Good job on the pics. That one is a keeper. Spooner, where'd ya get the cheap rear set brackets?? I have a set too....
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post #6 of 117 (permalink) Old 08-09-2008, 11:53 AM Thread Starter
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**ea6bmech**

I bought the rearset risers from some place on this forum a while ago.
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post #7 of 117 (permalink) Old 08-09-2008, 08:20 PM
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on a 07 zzr 600 do u have to take apart engine to get the trany case off?
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post #8 of 117 (permalink) Old 08-09-2008, 08:21 PM
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does the gears get damage to from the forks alot of the time i have 11,500 on the bike?
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post #9 of 117 (permalink) Old 08-10-2008, 03:29 AM Thread Starter
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I think every year before the 07 you have to split the case to change the gears. The gears don't always get messed up but my popping in and out did wear on the dogs for the gears. The teeth on the gears were fine though.
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post #10 of 117 (permalink) Old 08-10-2008, 11:50 AM
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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!
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