[VIC] Need Help

[icebreaker]

Hi Guys,


Well as some might know I have been having some issues with my 2nd gear selector forks giving way.
I have replaced the Fuchs oil (Fuchs can seriously go and get fuched!) I made the mistake of running fully syth for the trackday the weekend the problem
started to occur. The bike has spend 99% of it's life since in the garage. But recently it dawned on me what the change had been that seemed to cause the problem.

So I changed the oil last weekend and it seemed to give a minor improvement.

So what now you ask.... ?? no? Well you bloody should be asking...

I am in desperate need of putting together a small crew to assist me in pulling the engine out and sorting out the gearbox over the next few weekends.

Offering beer, sex, wife (14 weeks pregnant), 1st born for experienced help. I have a donor engine and happy to do it anywhere necessary.

At this stage Rossi and I have been discussing taking the bike and spare motor upto his place to get it done. But we are lacking someone with some experience
in doing this particular job on this engine.


Anyone able to offer some assistance???



Dan

[Strika]

Hey Dan, If it's just a motor swap, it can be done comfortably in a day with two people. I'de be happy to help for a few hours on Saturday if it helps. As for pulling the gearbox down, as long as you have a workshop manual, it's simple and can be done without pulling the crank apart. But it's a longer job and if it's not just worn selector forks or a worn shift drum it will be requiring a micrometer to mic up all the bits and some gauges to measure clearances when you put it back together with new clusters. It can be fiddly sometimes, requiring shimming to get it spot on. I personally would put that one in the hands of workshop (Mainly cause I'm over having engines in bits...I like em plug en play these days.

[Benno]

If you're swapping like for like it shouldn't be too hard. I'm more than happy to come lend a set of hands if needed, however it's definitely not my forte. Let me know when and where

[icebreaker]

It's not swapping engines.

The engine is an old zx6r engine and its condition is unknown, but the gearbox should be ok as a donor as i believe it had no box issues.

I'm hoping to just change the selector forks over if possible.

[MickLC]

In theory you can do selector forks with the engine still in the bike, but it can be a bit fiddly from what I've heard. Make sure you have a good look at the dogs on second cos if it's been popping out from the worn selector forks then they may be pretty munted as well. Might be worth pulling the sump off the second engine and checking it out first before pulling anything off the bike, then at least you can get a bit of a better idea what's involved and make sure you have decent bits in there at the same time.

One word of advice, make sure you have the sprocket off the engine before you take it out of the frame

[icebreaker]

Front sprocket isn't on very tight atm.

Might take the motor around to Rossi's on the weekend and pull it down and check what the spare box is looking like.

[Gosling1]

....... Make sure you have a good look at the dogs on second cos if it's been popping out from the worn selector forks then they may be pretty munted as well.......

+1

If the selector forks are worn, its almost *guaranteed* that the shift drum will also have corresponding wear, in the shift drum groove. When I did the box on the Pearl, the minimum width for the selector forks was 5.5mm.............the forks came in at under 4mm .... - and the maximum width of the shift drum groove is meant to be 6mm , it was about 7.5mm !! ie totally fucked. The dogs themselves were fine, it was all the wear in the shift fork groove that caused the jumping out of second gear.

I just did a gearbox swap as well out of another Z1000 motor, with selector forks and shift drum grooves that were in much better condition , and no more problems....

You need an accurate micrometer (inside) to check your spec's against factory specs.

Good luck mate, but its a pretty easy job if you have all the gear ready to go.