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Discussion Starter #1
Hey guys. My bike is back together and she was riding just fine for a little while but today when I went into 2nd gear I started getting very obvious clicking noises. Pull the clutch and it goes away, let it out and it’s back, definitely speeds up or slows down with wheel speed. Every other gear is fine (except needing a clutch replacement now... god why). Hoping it’s something related to the gear shift - seemed to have to increase my foot up-shift distance after it happened. Any clues?
 

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So you did something wrong or used old parts and they seemed to work for a bit and now dont?

Does that about sum this up, looks like you get more practice at taking things apart and "fixing" them................
 

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Discussion Starter #4
Transmission is from a bike with half the miles of my engine, everything but the throwout bearing was fine and functioned properly, I’ve replaced all the races and such. Not sure why used parts are a problem but either way I’m feeling like it’s a shifter/shift drum problem and not the trans itself. Pulling the pan this morning to investigate.
 

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Discussion Starter #8
Well at least you figured that out. Are you just going to buy a gear and replace it?
I have the original transmission - i found out after i bough this one that i simply had a loose sprocket nut that was causing a skip but put this trans in anyway. I don't really trust the trans in it now so I'm going back to the original. I’ll swap over any parts that look better. I’m not paying $120-$160 PER GEAR to build a new trans.
 

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Discussion Starter #10
Figured this time around I’ll just drop the bottom half of the crankcase out - shafts should come with it and wont have to take the whole engine out again.
 

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Discussion Starter #13
Will probably call a tranny place tomorrow and see if they can at least inspect the one I have that I want to put back in. I wonder if the gears could be heat treated to strengthen them up a bit.
 

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I wouldn’t bother. Is this bike that old? Kind of a lot of work for such an old one. 2009 or newer is a cassette. Easy and fast transmission swaps. Relatively
 

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As you found, the only way to split the cases is with the engine out of the chassis............. so you should be getting good at that by now- what is this 5th time or more???

Using old (used) parts is always a crapshoot.......... $70-$120 per gear is pretty standard pricing

And I would certainly go out and spend the $100 or so on all new gaskets your orange silicone shit slathered everywhere is disgusting, and it certainly is not the proper method to seal the case halves............. be the best $100 you could spend on the bike IMO!

So you think you are going to find a transmission specialist for a motorcycle transmission?????????
or are you talking about going to some car shop and have one of those knuckleheads tell you about your motorcycle transmission???
I mean they should be able to look at it and look for wear and they should know how it operates to know where to look- but beyond that they are likely clueless and even this may be giving them far too much credit for too many of them........... Always the pessimist!!! People are lazy fucking idiots- proven fact!

So what does the mating gear look like? - guess it does not matter if you throwing in your old trans that the c/s spun around and around on the output shaft........... (where is the picture of that damage?)

You did get very lucky in that, that piece of the gear tooth fell seemingly harmlessly into the oil pan rather than get caught up wedged between the input and ouput shaft gears and gernade your cases and engine......

cryo treating may make them brittle, heat treating, they already are......... you would be far better served to undercut atleast the upshift side and then ISF treatment to polish it all......... likely to run in the $500 range total for an entire trans (plus shipping to and from)

if all you are doing is riding it around on the street until the next thing breaks on your 20+ year old bike, and don't have a huge personal connection to the bike, just install oe parts and ride the bike.........
if on the other hand you don't mind spending the monies and actually having something, then spend the monies and hand someone will skills the entire engine and let them work the magic and then with a smile happily hand them a few thousand dollars for thier time and efforts and Thank them! (but yes, this would be more than the entire is worth now or ever)
 

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Discussion Starter #16
I guess I’m just figuring out now which route I want to go. Engine is apart again so i’ll take my time but we’ll see.

There is no “crankcase gasket” or anything, so what should I be looking for to use to seal the crankcase? I mean, they’re machined together right?

Only reason I say heat treating is that this is a 23 year old bike and probably same on the trans so with constant heat cycles the metal could be fatigued. And I believe the trans shop near me does some bikes but there is also a bike shop so either way I want to get mine looked at.

The sentimental value is all there. Honestly I could nuke this engine and I’d rather buy a used engine on eBay. Call it crazy but I love the way this bike rides and feels (when it does!).

We’ll see about undercutting.
 

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Discussion Starter #18
As you found, the only way to split the cases is with the engine out of the chassis............. so you should be getting good at that by now- what is this 5th time or more<img src="http://zx6r.com/images/smilies/rock.gif" border="0" alt="" title="Eh?" class="inlineimg" />

Using old (used) parts is always a crapshoot.......... $70-$120 per gear is pretty standard pricing

And I would certainly go out and spend the $100 or so on all new gaskets your orange silicone shit slathered everywhere is disgusting, and it certainly is not the proper method to seal the case halves............. be the best $100 you could spend on the bike IMO!

So you think you are going to find a transmission specialist for a motorcycle transmission<img src="http://zx6r.com/images/smilies/rock.gif" border="0" alt="" title="Eh?" class="inlineimg" /><img src="http://zx6r.com/images/smilies/rock.gif" border="0" alt="" title="Eh?" class="inlineimg" /><img src="http://zx6r.com/images/smilies/rock.gif" border="0" alt="" title="Eh?" class="inlineimg" />
or are you talking about going to some car shop and have one of those knuckleheads tell you about your motorcycle transmission<img src="http://zx6r.com/images/smilies/rock.gif" border="0" alt="" title="Eh?" class="inlineimg" />
I mean they should be able to look at it and look for wear and they should know how it operates to know where to look- but beyond that they are likely clueless and even this may be giving them far too much credit for too many of them........... Always the pessimist!!! People are lazy fucking idiots- proven fact!

So what does the mating gear look like? - guess it does not matter if you throwing in your old trans that the c/s spun around and around on the output shaft........... (where is the picture of that damage?)

You did get very lucky in that, that piece of the gear tooth fell seemingly harmlessly into the oil pan rather than get caught up wedged between the input and ouput shaft gears and gernade your cases and engine......

cryo treating may make them brittle, heat treating, they already are......... you would be far better served to undercut atleast the upshift side and then ISF treatment to polish it all......... likely to run in the $500 range total for an entire trans (plus shipping to and from)

if all you are doing is riding it around on the street until the next thing breaks on your 20+ year old bike, and don't have a huge personal connection to the bike, just install oe parts and ride the bike.........
if on the other hand you don't mind spending the monies and actually having something, then spend the monies and hand someone will skills the entire engine and let them work the magic and then with a smile happily hand them a few thousand dollars for thier time and efforts and Thank them! (but yes, this would be more than the entire is worth now or ever)
Trying to figure out what you mean by “C/S spun around” paragraph, but I'm looking at the APE website and may call tomorrow. I’m guessing I could send both sets of gears minus the broken one and they could use the best looking bits for the undercut. Their sight doesn't say anything about ISF treatment (idk what that is but sounds nifty). I think it’s worth the money if it’s solid stuff. Also here’s another pic of the damage; just a missing tooth making my clunking sound. Kinda weird.
 

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I guess I’m just figuring out now which route I want to go. Engine is apart again so i’ll take my time but we’ll see.

There is no “crankcase gasket” or anything, so what should I be looking for to use to seal the crankcase? I mean, they’re machined together right?

Only reason I say heat treating is that this is a 23 year old bike and probably same on the trans so with constant heat cycles the metal could be fatigued. And I believe the trans shop near me does some bikes but there is also a bike shop so either way I want to get mine looked at.

The sentimental value is all there. Honestly I could nuke this engine and I’d rather buy a used engine on eBay. Call it crazy but I love the way this bike rides and feels (when it does!).

We’ll see about undercutting.
THREEBOND which is also yamabond, hondabond, kawibond, suzibond.......is what you need for the crankcase mating surface.......... and excellent choice on all new gaskets for the oil pan, clutch cover, stator cover and ignition cover- although I would have went OEM

The transmission... as long as you never ran it out of oil......... will never get hot enough to effect the original heat treating of the gears, regardless of age or miles, especially not on a street engine


I’ve got cometic gaskets on the way for everything else case wise
Trying to figure out what you mean by “C/S spun around” paragraph, but I'm looking at the APE website and may call tomorrow. I’m guessing I could send both sets of gears minus the broken one and they could use the best looking bits for the undercut. Their sight doesn't say anything about ISF treatment (idk what that is but sounds nifty). I think it’s worth the money if it’s solid stuff. Also here’s another pic of the damage; just a missing tooth making my clunking sound. Kinda weird.
You said the original transmission was replaced with this unti becasue the c/s sprocket nut was loose/missing so the c/s sprocket was spinning on the shaft???


ISF treatment for the transmission.....................

There are several places that do quality undercutting, there are also a handful of very good ISF treatment centers, some also do undercutting so do not........
 
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