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Bent Shift Fork?

4K views 10 replies 5 participants last post by  ZoomSplat 
#1 ·
Hi Guys, I bought an 05 ZX6R from a dealer (Triumph). Came with a warranty but I'm in a bit of a situation.

Since I bought the bike the bike sometimes gets 'stuck' in 2nd gear. I cant shift up and I cant shift down (without considerable force, which I've only done once). There seems to be hardly any free play on the foot lever when this happens. It jams, so to speak.

I believe if I slip the clutch and partially engage the engine then try again I can shift (I can't be 100% sure this works every time. Tried it twice and seems to do the trick).

It is now back at the dealer for the second time. I have insisted they strip it down and look inside the transmission. They contacted me today and said they can see no signs of premature wear.

I've spoke to a Kawa dealer and he said it sounds like a bent fork selector but he can't be sure.

First of all, do you any of you have any idea what this could be?

Secondly, if the fork selector was the culprit would the damage/bend be large enough to spot with the naked eye? What is the tolerance for error here?

Should I insist they replace the fork anyway?

Thanks for your time!
Lee

EDIT:
Forgot to add I would say this problem occurs more if I run the bike cold (<50oC). Again this could be co-incidence but it seems to be that way.
 
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#3 ·
^+1

If you have them replace it, they'll likely try to charge you for the labor since they have stated there is no malfunction. You can calmly state that there is very obviously a problem with the bike, and it IS in fact a major internally lubricated part and will be covered under the fine print of the warranty they offered with the purchase of the bike. You will gladly pay for the parts out of your own pocket but you are most certainly not going to shell out cash for labor to fix a problem that is covered by the warranty.
 
#4 ·
thanks for the replies.

the 05's are notorious for 2nd popping out of gear though correct? This is a little different. It never pops out. It gets jammed in 2nd. Also they have stated there is no significant wear on the gear.

They haven't mentioned anything about charging me. They seem like a decent bunch and have done everything I have asked of them.

Does anyone know if they can tell if the fork is bent just by looking at it?
 
#5 ·
This has happened to me a time or two on my p model. But it was when I first got it and was getting be into the non-gp style normal pattern (ran gp on my 954) and there was a few times where I would get lazy and not shift all the way into 2nd from 1st and it would get stuck in between gears and I'd have to pop the clutch to get it back out, which makes a horrible sound. But as far as I know when forks are bent they just pop out of gear, never heard of one getting stuck in gear.
 
#6 ·
Your problem could be in the drum , if 2nd gear get missed a couple of times the drum wher the fork move in get dented ( i had 2 drums thrown away because of this) and if the dent is big enough it could cause this , when i say big enough doesnt mean you have to look for some big damage on the drum its just a small dent but with big cosequences.
 
#11 ·
Here, so you know what they're looking at:

Auto part Metal Automotive engine part Crankshaft Brass


You can see the drum that Nexia is talkign about, second shaft from the left. On either side of that are the shift forks. They don't go where they are placed in the picture, but it gives you an idea of what the parts look like. The fork is basically just a big metal C that rides on the gear and the shift drum pushes it to engage or disengage that gear.
 
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