ZX6E 2nd gear problem. - Sportbikes.net
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post #1 of 12 (permalink) Old 12-29-2004, 12:15 AM Thread Starter
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ZX6E 2nd gear problem.

All of a sudden, whenever i tried rolling hard on the throtle in second gear, the bike would jerk pretty bad, it felt like the chain was slipping. Once my rear tire locked up. This happens when i try to wot in second gear, when i do it gently, it doesnt happen.

Strange thing is, when i downshift from 3rd to second, this problem dissapears and it only happens when i switch from 1st to second.

Is the second gear stripped, or is it the sprockets not coming on top of each other completely creating slips?

What do you guys think.

Thanks in advance.

ps. if this is second gear that is stripped, i would do the swap myself. There was a website with detailed pics of step by step process, but i cant find it anymore.

ps2. its a 1996 zx6e with 9700 miles. I got the bike with 5940 miles. It started happening around 9300-9400 miles.
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post #2 of 12 (permalink) Old 12-29-2004, 07:29 AM
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What happens is probably a combination of a couple things. Worn shift forks and rounded engagement dogs. The shift forks get worn and or bent which doesn't engage the gears all the way causing the engagement dogs to round off. That causes them to slip by each other under accelleration. The only sure fix is to pull the engine, split the cases and see what parts are damaged. Probably 1 or more shift forks and at least 2 transmission gears. It's a pain in the butt to fix but it is fixable..
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post #3 of 12 (permalink) Old 12-29-2004, 01:09 PM Thread Starter
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Quote:
Originally Posted by ZXLNT
What happens is probably a combination of a couple things. Worn shift forks and rounded engagement dogs. The shift forks get worn and or bent which doesn't engage the gears all the way causing the engagement dogs to round off. That causes them to slip by each other under accelleration. The only sure fix is to pull the engine, split the cases and see what parts are damaged. Probably 1 or more shift forks and at least 2 transmission gears. It's a pain in the butt to fix but it is fixable..


So i am gonna have to pull the engine out. Damn.

I guess, going by the book its not really that hard to take it out.

Last edited by SebG; 12-29-2004 at 01:12 PM.
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post #4 of 12 (permalink) Old 12-29-2004, 11:06 PM
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yeah dude sounds like your forks.
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post #5 of 12 (permalink) Old 12-30-2004, 08:58 AM
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More the gears themselves than the forks. The engagement dogs and slots in the gears get rounded off and then slip out under hard accelleration.
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post #6 of 12 (permalink) Old 12-30-2004, 04:16 PM
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go to http://www.zx6e.com/forums/ it is a site dedicated to the 6E which i also have. By the way they are notorious for second gear problems or thats so i'm told. hope this helps.
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post #7 of 12 (permalink) Old 12-30-2004, 04:59 PM
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I have a 1993 zx6e and I fixed the second gear problem, but it was not an easy fix. As ZXLNT said, the engine has to be dropped and cases split, and then if the good lord willing, you will be able to identify which parts you need. I ended up needing two forks and two gears. Both of the gears were on the output shaft. It turned out to be a terrible pain to fix but it was a good learning experience. Hopefully you have plenty of patience and good mechanical knowledge before you attempt to fix this yourself. I would like to also say that it was no small feat to get the friggin motor out of the bike. Took me darn near forever. After pushing and pulling and almost breaking my arm I finally got the stupid thing out. I don't even want to talk about putting it back in. Also, if you decide to do this, I found out that there were two different types of gearsets, some had six dogs while others had five, be sure to order the right ones, because I got in too big of a hurry and didn't. Hope I was able to help.
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post #8 of 12 (permalink) Old 12-30-2004, 05:12 PM Thread Starter
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Thanks for the tips guys.
I have a pretty decent mechanical knowledge+ i can always have my dad help me out cause hes a mechanic.
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post #9 of 12 (permalink) Old 12-30-2004, 05:15 PM Thread Starter
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Yes, i found the site that i was looking for

http://roy.shaptech.com/gearfix/
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post #10 of 12 (permalink) Old 12-30-2004, 05:22 PM
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Usually its 2nd and 6th gears I think


13260D and 13260G The dogs get rounded off on one and the slots get wallowed out on the other gear.. and that lets it pop out of gear..
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post #11 of 12 (permalink) Old 12-30-2004, 06:14 PM Thread Starter
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Well, its not popping outta gear, its more like its blockign my rear wheel.
Once my rear tire actually locked up because of it. When i do wot in second gear it jerks violently.
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post #12 of 12 (permalink) Old 12-30-2004, 07:37 PM
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Same difference and same damage and same procedure to fix. The dogs and slots skip by each other under hard accelleration....
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