Kawasaki Sportsbike Riders Club - Australia - Online Forum

Ok,


Well looks like I'm losing 2nd gear...

Looking for some advice and feedback on what I'm up for and what I should do.

Had a chat to Paul from Wet4U and he advised that it sounds like the box and not a jetting issue/clutch issue like I first thought it was.

Basically I can feed 2nd a small amount of throttle, but the moment i open it up abit it starts to surge/jolt and then grab and repeat. Over the past couple of rides it has gotten a tad worse.

I was wondering if I-K's '99 engine would be an option for getting gearbox parts... *shrugs*




Dan

You can pull the box apart without removing the crank mate. Just remove the motor, tip the fucker upside down, drop the lower case off and voila one gearbox. Then have a look at all the bits insisde and see which bits are worn, remove, remachine/replace with good bits and then stick the lower case back on! Should be able to sort in a decent bourbon session mate! May as well sort the frame while your at it!

Could just be a stripped tooth, a cheap repair if you have the time to strip it down yourself. Is a pain splitting a box as they are sprung, and need to be opened little by little. I learned that one the hard way You could use one of the straps I lent you. Tighten around box, undo screws a couple of turns, losen the strap, to allow the box to open to the screws. Re-tighten the strap and repeat. Simply removing the casing is like playin 52 card pick up!

I have no idea how to get the engine, etc out and back in. let alone working on a gearbox.. more than happy to get my hands dirty with some assistance and direction.

Was told I could be looking at 1-1.5K.

looks like the full arkra is going back up for sale to fund the gearbox.

Sounds like the dogs on second are worn.

The dogs are the bits cut into the side of a gear that allow it to connect to it's partner to "lock" into place on the shaft.

When they wear, they don't grip as well and the gear can slip off causing the issue you're describing when you give it berries.

Nothing you can do except rebuild the 'box by either replacing the offending gear (preferably gear pair) of getting the dogs "undercut" to give the grip back.

either way, You'll need a manual and lots of beers.

Or a chequebook.

Sorry mate

I've got the manual.. It's a big sucker, so I assume it goes into that... Beers.. Check... Bourbon... Check... A Clue... Bugger!


lol

Winters coming.. so looks like it's a case of 1st..... 2nd. 3rd.......... and worry about it when winter comes into full swing.

short shift mate..short shift...lol

Just gear the fucker to the moon mate. That way you start the race in third!!!!

Have you read my bit about fixing the gearbox on the old 9? It'll give you an idea of what you are up against, but you can save a fair bit doing it yourself.

Mick: No I haven't, got the URL?


Cheers,


Dan

Thicker oil... then sell it...

icebreaker wrote:Mick: No I haven't, got the URL?


Cheers,


Dan

Here you go http://www.ksrc-au.com/index.php?itemid=91

...any questions just ask

looks rather complicated, esp considering it is more about over coming issues with 2 different models of gearbox. But thanks mate!

Strika wrote:You can pull the box apart without removing the crank mate. Just remove the motor, tip the fucker upside down, drop the lower case off and voila one gearbox.

sounds easy but have u picked up an engine and tipped it upside down before, hercules.

icebreaker wrote:I have no idea how to get the engine, etc out and back in. let alone working on a gearbox.. more than happy to get my hands dirty with some assistance and direction.

Was told I could be looking at 1-1.5K.

looks like the full arkra is going back up for sale to fund the gearbox.

I had to replace the drum/2 cogs/secector fork and seals on the 7, waited a month and a half and the bill was $1800 (no labour)
Check out prices first, bike shop wanted $1200 just to pull it out and look at it