Kawasaki ZX-6R 636-C1 2005 — Problems with 2nd gear

M

missmyhonda

New member
I have some problems with 2nd gear when switching from 1st and RPMs are higher 4000. I could hear metal rasp. When switching on lower RPMs looks like everything fine. First time I faced with this when tried to switch from 1st to 2nd at 8000+ RPMs with no success, looks like it stuck between gears.

I've googled and looks like it common problem for kawasaki 04-05 model years. I just need someone to take a look on what should be replaces and order parts.

Please advice service not far away from Mountain View.
 
Maddevill

Maddevill

KNGKAW
2nd gear is usually the first one to go tits up when someone takes off at full throttle and misses the gear change. The gears slam the shift fork over and bend it as well as the shift dogs can get rounded off. Fixing involves splitting the cases. If you are going to fix it, have them undercut the gears while they're at it.
 
N

NorCal Factory

Well-known member
Zx-6

Great bike!
I had the same bike for five years and had the same problem.

The good news is that it could be the shifter forks and you can replace them without taking the engine out. Just remove the oil pan.
The bad news is that they cost $85 x2 and that might not fix the the problem. It did not for me.

If you pull the engine and start replacing trans gears they are about $185 for the two parts for each gear plus gaskets and you would want to replace the shifter forks and a pro circuit shift star upgrade for another $150 or so.

Net result I bought a new / used motor for $1,000 - it was cheaper than the parts to rebuild the transmission. Many other mechanics and track day /race guys advised the same.

These days there are fewer mechanics that are worth trusting to replace transmission gears.

I sold my old motor to evolution suspension and he replaced the gears so at least they know how to do the job if you are looking for a mechanic to fix yours.
 
You must log in or register to reply here.
Top