06 ZX6R Transmission :(

[robracer]

Wow sinking your teeth in, nice to see you giving it a go

[bjn_42]

Its a weird feeling not knowing what exactly what to do, only the general idea. I've got all my bolts in containers or screwed back in plus I'm taking heaps of photos. This weekend should be interesting.

[Johnnie5]

Few questions just to clarify:

When you say decelerating; how fast are you going when you're entering first? Are you trying to match the engine revs to the speed by blipping then throttle?

When you say slipping do you mean the gear is dropping in and out or that the bike is bouncing/chattering at the rear after you let the clutch out?

Roughly 40 - 50km/h ' ish nothing extreme. And no, not blipping or anything fancy, just a simple downshift.

shifting diwn into 1st at 50kph without blipping the throttle seems a little extreme to me and weird things hapening wouldnt be out of the ordinary

you say now you are pulling the motor and taking it to a mechanic , did you have the mechanic ride it yet ? or just pulling the motor and say hey i have
this problem andplease fix it

[bjn_42]

No, I took it to a mechanic to analyze the problems and he said he could only be certain if he opened it up. To save money I'm doing the work myself. Just to clarify, there is a problem with the 1st gear, its not the chain and I highly doubt it's the clutch. My mechanic seemed to think it could be the selector.

[Kwakked Up]

Hi bjn

Not quite sure what you mean by slipping but if you had a problem with selectors or drum I would be thinking she would jump in and/or out of gear. It is all mechanical drive so the only place anything can 'slip' is the clutch.

I had a problem with my zx6rr for a while it felt like it was missing when in fact it was jumping in and out of gear, yeah sounds weird but had to strip her down and undercut the gears to keep it in gear under load. My point is that you need to diagnose problem first otherwise you will get it stripped down and everything will all look fine, then you might end up buying shit you don't need.

It is fun pulling stuff apart so good luck with.

[bjn_42]

In pulling it apart in going to check out the clutch. Since iv started researching this I've found a lot of these bike having a similar issue so I'll feel better taking a look.

small update: everything is off except the engine mounting bolts. Should get to drop the engine out on Wednesday. I'll post up pics of the gears and everything when I can.

[bjn_42]

Now the engine is out so I cant start fixing things

[bjn_42]

Bought a clutch gasket so I can remove the cover and everything to have a looksee at my fork selectors and gears. I only realised that i forgot to drain the oil before dropping the engine out. Learning everyday hahah

Does anyone know where i can find a clutch holding tool for relatively cheap? I have been looking and the cheapest I can find is $50 and for something I might only use once I dont want to spend that much...

[bjn_42]

Finally got round to draining the oil and removing the clutch cover and basket. Then I found out that the clutch hub nut is not a socket size that I have. I'm not sure but I think its 27mm because I went and bought a 28mm (think it would be an even number) and it was only just too big. Does any body know if the clutch hub nut is 27mm???? Im heading out tonight to replace the 28 with a 27mm and hoping for the best....

Anyways here are the photos

[Wattie]

Shoudl be a 27mm. Same as counter shaft sprocket nut

[bjn_42]

Awesome thanks. I buy a 26mm on the way home from work to be sure. The last thing i want to do is strip the nut

[Wattie]

Make sure its single hex.

[bjn_42]

The clutch hub nut is 27mm. Found that out after buying a 28, 27 and 26mm sockets haha. I also found out that clutch hub nut is one of the hardest nuts to get off. I tried tonight and gave up but sprayed some lubricant on it hoping that would do something overnight.

[bjn_42]

After trying for about 6 hours i finally gave up on the clutch hub nut and drove my engine down the mechanic. He took the nut off in 2 seconds...



Then i found the culprits



No one mentioned that the third selector fork was harder to remove than the other two. I had to take the drum out to get the last selector for out.

All three of the selector forks look rooted so im going to order three new. Does Anyone know where to order them from?

I have looked here http://www.mototech.com.au and they have them but they are kind of expensive so If anyone knows any place cheaper I cant get oem parts that would be great.

While Im waiting for parts i have sealed the motor up...

[Wattie]

Partshark