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View Full Version : Transmission, it's out. Now what?


nater123
04-28-2009, 11:16 AM
Okay so like alot of people, my seconde gear was jumpy and messing up. I would shift into 2nd and give it a little gas and it would go no where and rev or jump back down into netural.

So people are saying don't try and fix just buy a new engine. Well I took some advice from Ray and some others and did it myself. I got it all disasembled and split the cases. The labeling of every part in bags hopefully will save me any trouble's assembling and my manual.

With the cases split, I look and check all the gears look fine. No chiped or ground teeth or metal shavings. I have the shift dogs out too, but I don't know were to go with this now. What is my problem? Or what will determine what I have to replace. I got some pic's all update later if it will help. Any advice, please and thank you!

suzukiray
04-28-2009, 01:14 PM
You mean you have the shift FORKS out also? I need some CLEAR pics of the dogs on the TRANS gears & the receiving slots they go into. Ray.

arsenic
04-28-2009, 01:30 PM
getting a manual would help too :dunno:

nater123
04-28-2009, 02:47 PM
-getting a manual would help too :smt102

^^The labeling of every part in bags hopefully will save me any trouble's assembling and my manual.

I took the pic's and will update them onto here when I get home. I also took a video of the side to side play of the gears. Hopefully it helps.

Arsenic- Do you have carb parts? I need the plug that goes over the jet and then orings for the tops of the carbs by the vacums.

arsenic
04-28-2009, 03:15 PM
uummm, I buy all those carb parts new from BikeBandit. That's not something you want to use used parts on. :dunno: That reminds me, I got a set of carbs today I gotta rebuild for someone, BBL. :lol:

nater123
04-28-2009, 03:50 PM
If I sent you my carbs would you be able to sync them for me? My bike is stock 93 600f.

Here are the pic's hope they help!

Video of my gears, anything look out of movement or place?
YouTube - Tranny


http://img402.imageshack.us/img402/6515/img00187.th.jpg (http://img402.imageshack.us/my.php?image=img00187.jpg)
http://img134.imageshack.us/img134/8758/img00186.th.jpg (http://img134.imageshack.us/my.php?image=img00186.jpg)
http://img520.imageshack.us/img520/7448/img00184.th.jpg (http://img520.imageshack.us/my.php?image=img00184.jpg)
http://img530.imageshack.us/img530/7069/img00188m.th.jpg (http://img530.imageshack.us/my.php?image=img00188m.jpg)
http://img205.imageshack.us/img205/7336/img00190.th.jpg (http://img205.imageshack.us/my.php?image=img00190.jpg)
http://img156.imageshack.us/img156/1236/img00192.th.jpg (http://img156.imageshack.us/my.php?image=img00192.jpg)
http://img237.imageshack.us/img237/3271/img00193.th.jpg (http://img237.imageshack.us/my.php?image=img00193.jpg)

Cheriff
04-28-2009, 03:55 PM
Your best bet would be to rent the morgan carbtune from TheCyberPoet after you get your bike all back together. Arsenic is pretty good, but he needs your bike there not just the carbs in order to do a sync.

nater123
04-28-2009, 04:05 PM
Yeah that's what I figured. Is it pretty self explanatory and easy? What is 25 for the week if everything goes back right I get my 130 dollar deposit back?

Im trying to find out or decide if I just need shift forks (dogs) or a whole new tranny... any help guys?

Psycho1
04-28-2009, 04:20 PM
Can't really see what the dogs looked like in the video or pics you posted. Need to see the dogs on 2nd, and the slots in 6th where those 2 lock together to see if one or the other (or both) is rounded off.

nater123
04-28-2009, 04:27 PM
Would I for sure be able to tell if it was the dogs or is it pretty hard to see?

Cheriff
04-28-2009, 04:33 PM
[quote=nater123;1705803]Yeah that's what I figured. Is it pretty self explanatory and easy? quote]


Yea, its easy. I've done it and I probably wouldn't try what you are doing now. One little pointer I can provide is that you should get some replacement rubber caps ready. The caps on the vacuum ports were basically destroyed in their removal.

hardlydangerous
04-28-2009, 04:54 PM
hard to tell by the pics
ok so lets assume the gears and dogs are ok... to the gears have play on the shafts, can you rock the gears or are they a tight fit on the shaft...
check the forks for heavy hear or scoring... thats a sign the shafts are worn and wearing hard on the forks... This can cause the gears to jump out just as worn dogs will

The CyberPoet
04-28-2009, 09:18 PM
http://img134.imageshack.us/img134/8758/img00186.th.jpg (http://img134.imageshack.us/my.php?image=img00186.jpg)

I'm seeing a lot of wear on the end of that fork... hmmm...

Cheers
=-= The CyberPoet

suzukiray
04-28-2009, 09:43 PM
That fork is BENT! That's the ONLY way it gets worn like that in that area. Your trans MIGHT be ok but I just can't see well enough in the video or pics. Ray.

nater123
04-28-2009, 10:33 PM
Thanks for the input. Yes I think the forks are bent or atleast there scored and kind of worn. So I baught a used tran's and forks and shift drum. So hopefully this fix's my problems :).

You know the oring on the tops of the carbs by the vacums. If I didnt have any there do you think that would have created my iratic idle?

Right on, thanks alot for the heads up and tips (cheriff)

steves
04-29-2009, 06:31 AM
You know the oring on the tops of the carbs by the vacums. If I didnt have any there do you think that would have created my iratic idle?



Could have.

The CyberPoet
04-29-2009, 08:03 AM
You know the oring on the tops of the carbs by the vacums. If I didnt have any there do you think that would have created my iratic idle?

Yup. At least a massively contributing cause if not the cause.


That fork is BENT! That's the ONLY way it gets worn like that in that area. Your trans MIGHT be ok but I just can't see well enough in the video or pics. Ray.

Click the photo, then when the imageshack pic loads, click it again for a massive version.

Cheers
=-= The CyberPoet

nater123
04-29-2009, 08:52 AM
Right on well good deal, Figure something new out each day I tell you. Thanks for all the help guys. I hope this thing just perrs when everything back together.

Cyber, whats the price for renting the motion pro? I know like 125 deposit or what not but 25 a week did you say?

The CyberPoet
04-29-2009, 10:20 AM
Cyber, whats the price for renting the motion pro? I know like 125 deposit or what not but 25 a week did you say?

$5/week plus postage and paypal fees on the total of those two.
Details in the second post in this thread: http://katriders.com/vb/showthread.php?t=58596

Cheers
=-= The CyberPoet

nater123
04-29-2009, 11:11 AM
Thanks. All be getting to that by next week hopefully, You should see the mess I have rate now. I have everything disassembled and in bags or labeled. I mean I have the front end off the rear and swing arm, engine in 100's of pieces and bolts. Im putting in the new tranny and shift forks and while im waiting for the parts to come sometime this week I stripped the frame so I can paint it. What a project I tell ya she better luv me after this one. haha.

The CyberPoet
04-29-2009, 11:22 AM
If you've got the swingarm off a pre-98, this would be the obvious time to replace the swingarm bearings...

As for the frame, either powder-coat it, or use this stuff:
http://www.por15.com/HARDNOSE-PAINT/productinfo/HNGB/

Cheers
=-= The CyberPoet

nater123
04-29-2009, 11:52 AM
Could I prime and use a base at the top? I know that is anti rust and stuff but I am looking for ethier a gold or a chromish color. As you can see I have gold rims, black body with metal flake.

When are you getting new shift kits and how would they benefit me Cyber?

Thanks again!

The CyberPoet
04-29-2009, 04:31 PM
Could I prime and use a base at the top? I know that is anti rust and stuff but I am looking for ethier a gold or a chromish color. As you can see I have gold rims, black body with metal flake.

They have a dark and a light yellow version of that paint -- if you went to the webpage, you'd see the color choices further down.

When are you getting new shift kits and how would they benefit me Cyber?

I hope to have more in late this week (should have already arrived, but haven't)...

As for everything you ever wanted to know about shift indent kits, I slapped it into the Wiki here:
http://katriders.com/wiki/index.php5?title=Shift_Indent_Kit

Cheers
=-= The CyberPoet

GytRDunKat
04-29-2009, 04:55 PM
As for everything you ever wanted to know about shift indent kits, I slapped it into the Wiki here:
http://katriders.com/wiki/index.php5?title=Shift_Indent_Kit

Cheers
=-= The CyberPoet


Not included in the kit are the banjo bolt crush washers for the oil cooler hoses (which connect to the oil pan). If you remove the oil cooler hoses at the top (where they meet the cooler) instead of at the oil pan, this won't be an issue (the top connections use a rubber reuseable o-ring style gasket).


:cursin Now I read that! Duh!

nater123
04-30-2009, 11:13 AM
So I need new gaskets for the bottom oil lines from the cooler? Im waiting for my tran's, and couldnt be more excited to have everything run smooth and 2nd gear again :). All update with pics, I painted the swing arm chrome and frame gold.

The CyberPoet
04-30-2009, 11:29 AM
So I need new gaskets for the bottom oil lines from the cooler?

If you removed the oil lines at the oil pan, yes, you need new copper crush washers for those bolts. They are an one-time use item.

Cheers
=-= The CyberPoet

nater123
05-01-2009, 11:43 AM
Any clue were I might buy those? The top line on the side of heads leaked abit when I had the bike before I disassembled, is there one there too?

Is there any real way to see if my shift dogs are working properly when I put the new (used tranny and shift dogs in). The guys said they are good and will work and said I can return them if they don't but he hasnt ran the bike he got the engine from someone else and the money to me isn't the problem it would be assembling and disassembling a whole nother time.

md86
05-01-2009, 01:42 PM
I've yet to replace my banjo bolt washers , and I've reused them MANY times :dunno: . Not that my examples are always the greatest to follow :thinking . I mean , I DID ride into the side of a hill and slide headfirst into a tree last weekend :smt011 .....

The CyberPoet
05-01-2009, 01:45 PM
I've yet to replace my banjo bolt washers , and I've reused them MANY times :dunno: . Not that my examples are always the greatest to follow :thinking . I mean , I DID ride into the side of a hill and slide headfirst into a tree last weekend :smt011 .....

WTF? How come this is the first I'm hearing of it... Are you OK?

Cheers
=-= The CyberPoet

Newbie2it
05-02-2009, 01:43 AM
I mean , I DID ride into the side of a hill and slide headfirst into a tree last weekend :smt011 .....
Ok.. How does one ride into the side of a hill? Last I knew, hills had up sides and down sides... not many walls to them.

As for sliding into the tree head first.. Well..... Since your here to tell this tale, I assume you bounced off the tree. :nonod

But yeah.. Fill us in on the details.

mreedohio
05-02-2009, 03:52 AM
check n.ky weely ride thread in midwest forum and check parts wanted for the threads

nater123
05-04-2009, 11:13 AM
Everything is back together and seems to be working great. Oil pan was leaking so I am going to check that out and see were the leak is coming from (bolt or gasket). The neutral sensor broke so oil is leaking out of there but I think I sealed that up. I also cleaned the carbs top to bottom and replaced o rings.

I will update with pic's and information. I hope it all works out, testing next hour I think.

Thanks for all the input and help guys!

fzr600straightfast
05-05-2009, 12:08 AM
i hade the same problem there are two gears for second gear and the teath dont break off the squar nubs on the out side and inside wear down i can send you a picture of what i mean tomorow

nater123
05-05-2009, 08:41 AM
Yeah I know that's what mine looked like. I replaced the gears but the drivin look fine so I left it and also replaced the shift forks.

ctandc
05-05-2009, 12:36 PM
So is it fixed?