Gears, Clutch... 2nd? Help!?

[nater123]

Good day Kat's!

The name's nate, 1993 suzuki kat 600f. So I just got my temps and paided up the coarse fee's and the 520.00 dollars in insurance. Everything works smooth but when I shift into second gear it revs up high and clanks around down there for abit and will go hard into neutral or sometimes remain in 2nd but no good acceleration. I shift up hard enough, I know that isn't my problem. All the other gears seem to work perfect, Is it a clutch or 2nd gear burnt out or just adjustments?

I have done my fair share of work with this bike coils, all the fairing work, cleaned the carbs 3 times and more. I don't want to just let it go but bought it not running so I guess that's what I get, right? .

Any help or information would be great! Sites were to get parts, what I should replace, or your 2 cents. I want to get her working like a beaut and back on the road asap.


THANKS ALOT GUYS!

[RossW]

transmission rebuild time most likely. The 2nd gear failure is a typical failure mode for the kat transmission.

[nater123]

Right on, now some of the other fourm posts I was checking out say to buy a new engine. What all am I looking at if just 2nd gear is giving me a problem when I ride? I have the chilton and will follow that step by step for the most part. I need a whole rebuild kit or just a 2nd gear? Anything else I should replace when I am down there? How hard of a project am I getting myself into.. ? Whats a good site to buy the parts, anyone?


Thanks!

[Cheriff]

I can't help talk you through it, but I know it involves splitting the cases. Its about the most complicated repair to do. People advise to buy a new engine based on the time taken to complete the fix.

[nater123]

Right on makes sense. I am 16 years old, this is my first bike. The gear was gone or about gone before I baught the bike, I am now finding out.

I know time is money, but I have 4-6 hours a day in my school shop for auto with all the tools and stuff. I got my chilton all printed off, like 200 pages haha! I am ready too do this and just need to know if it is worth it, how hard the job itself is once I have the engine out and split the casing. I know that getting the engine out and having it on the table won't be much of a problem. I just need to know if im not super experienced how hard it's going to be to replace 2nd gear. Then at most what parts I need or should look at replacing? Like I was saying, I shift into 2nd and it jumps around down there drops to netural or I shift up to 3rd before I sit in the middle of the street listening to the rpm's jump high.

[suzukiray]

Splitting the cases is not that difficult! I'm not sure why most on this site seem so scared of doing it but it is less than a full day job to remove the motor, split the cases, drop in a replacement trans, re-seal the cases, & put the motor back in the bike. If you decide you want to give it a try, I have 2 GSXR 750 6 speed transmissions for sale for 175 each + shipping. Let me know if you are interested. Ray.

[nater123]

Right on. Yeah getting it out and taking everything off to jack the motor out, no problem. I have had the thing to bare motor a couple times. I just don't know about the tranny or 2nd gear itself? Would I want to throw in a whole new tranny or just 2nd gear if nothing else but 2nd slips. Would a 750 work in my 600?


Thanks guys, appericate it all more then you know!

[suzukiray]

I would change the entire trans so you don't have the motor apart waiting for new parts & risk getting crap inside while it's open & parts getting lost. Yes, the OIL COOLED 750 trans is a bolt in. Ray.

[baker2011]

ray.. I am thinking i may be starting to have this same problem with my bike i have a 93 kat but my second gear works fine until i really give the throttle hell, when i pin it it feels like it starts slipping around 7-8k RPM, would this be second gear in the process of going out or my clutch slipping? it only does it in second ? PM w/advice please I may be interested in one of your motors

[suzukiray]

If it only does it in second, it is the trans. Ray.