04 zx6rr gearbox strip

[bobtrx]

G day all had a problem with a down shift 4th to 3rd at the track ,hit a false neutral then it crashed into 3rd . Rest of that session no problems . Next session running along in 3rd or 4th it did what seemed like the chain jumping a tooth on the rear sprocket then next down change problem shifting down now can't get the box down below 4th.Placed the bike on race stands and pulled off the clutch cover to check the external shift mech , looks ok and works to get 4th to 6th and back again while turning the rear wheel by hand . I think it is remove motor to check for bent shift forks . Is there any other check I can do before removing the motor? I don't have the clutch special tool for holding the basket to allow removing the hub nut , can I rattle gun it off ( anti clockwise ? )if I lock the rear wheel or is that a no no

[mike-s]

Yes even though it isn't the optrimal way of doing it, you can still do it, just make sure you use something with a bit of give like a 2x4 or so and have someone brace the wheel firmly against the wood..

[bobtrx]

Used a rattle gun on both clutch and rear sprocket nuts and they came off piece of piss . My next tool to buy . I quite looking forward to dropping the donk and having a look inside . Just have to make a tool for the frame spacer bolts .

[bobtrx]

Opened up the cases and found the problem , not enough fluoride in the water makes your teeth weak . Parts have gone to my local bike shop to be replaced . The cases have been split before and the gears are undercut , I will find out if that is standard on this model or the gears had to be done . Looks to me like the harding has gone from the gear teeth or is it just fatigue . Does this happen to kawa gears ? I have pic's of the job so far

http://s64.photobucket.com/albums/h169/ ... 20GEARBOX/

[timmyrocks]

pics not working for me mate, i dont have photobucket

[bobtrx]

[bobtrx]

Priced new gears etc $1600.00 so tried vic wreckers ( Rob) who had a complete gear set for $750.00 . Posted to me and now installed . Good service , prompt and knew his stuff. What do you track boys use to protect the clutch cover and timing cover from sliding down the track mishaps

[robracer]

Mate to dont protect .... replace..... go NRC covers they are the ducks guts & quite reasonably priced + there is a local distributor Kenma in Syd that has most off the shelf Call Sam at MAW 02 9634-2014

http://www.kenma.com.au/nrc.html

[bobtrx]

Took the bike to the local airstrip for a run to check for oil leaks and how the new gearbox worked .All went well so on go the fairings and slicks , next stop PI. Not been on a bike for awhile it felt pretty quick but that soon changes after a few laps.

[mike-s]

Glad to hear you've got new gears sorted.

p.s. where the hell are you? broken hill?

[bobtrx]

Don't let our MODERN air wing or state of the art runway fool you into thinking this is a Big city , lucky for me I couldn't get the tiger moth in the pic . It was off doing the mail run to the outer district . This location is only a hop , skip and a jump from the next great meeting point of kawa riders , Halls Gap . A sleepy little hollow called stawell