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+--- Thread: Transmission Issue (/showthread.php?tid=43488)
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Transmission Issue - NYStunter636 - 09-15-2012
Bike: 05 636
Problem: Bike slips out of gear. Under power and sometimes on idle..
I know I'm not the first person with this problem. Do I have any options before I pull apart the transmission. Example, Ziptie the shift lever down.
I've been told its most likely the shift forks. Looked up how to replace them and it doesn't look difficult. Can I use the shift fork from another gear, 5-6 gear, in replacement of the one that is slipping, 1-2? They are the same. I'm never in 5-6 gear...Do I "need" all of the shift forks?
Just looking to make it through this weekend without getting randomly ejected.
Transmission Issue - kawi636braaap - 09-15-2012
Never rebuilt a bike transmission but I have done a few GM ones and Volkswagen before. I doubt you can reuse the shift forks on different speed gears because there most certainly different lengths. Im gonna say based on experiance its probably your syncronizers. Theres a brass blocker ring that constantly rides the taper of the speed gear and its the most likely part to wear in any constant mesh. When it wears slippage could result. Your absolutely sure its not your clutch slipping?
Transmission Issue - StrictlyStunt - 09-15-2012
Might be some help...
http://stuntride.com/vbstunt/showthread.php?t=39631&
I know there's another thread floating around here somewhere specific to the shifter forks.
Transmission Issue - ~03~raven - 09-15-2012
If it just started you could try just changing the shift forks in hopes that your gears don't have rounded dogs yet. You can change those out with the motor still in the bike and without splitting the case just going through the oil pan.
But gears could be too far gone, so the shift forks alone won't fix that. Also you got to make sure you get the fork back in ride because if you don't it will slip worse and be hard to shift, or not shift. If you got the ability to just drop the motor and replace the forks, the bar guides, the shift cam, and the gears. That is what will fix it and if you can like that link above go get them undercut. If not everything will be ok but you never know when the other tranny might let loose.
Transmission Issue - kirny - 09-18-2012
Quote:
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Originally Posted by kawi636braaap
 Never rebuilt a bike transmission but I have done a few GM ones and Volkswagen before. I doubt you can reuse the shift forks on different speed gears because there most certainly different lengths. Im gonna say based on experiance its probably your syncronizers. Theres a brass blocker ring that constantly rides the taper of the speed gear and its the most likely part to wear in any constant mesh. When it wears slippage could result. Your absolutely sure its not your clutch slipping?
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Transmission Issue - kirny - 09-18-2012
no swapping the shift forks will not fix your issue fyi there are only 3 of them also if it is popping out of gear then you are beyond shift forks i only say this because i have seen other people INCLUDING ME tried to just change the forks and it didnt do shit so i took everything apart put it all back together just to take it apart and again.......anyways my suggestion to you is to get a used transmission and just swap out the shafts or get new gears and put them on your old shaft
Transmission Issue - JohnnyP - 09-18-2012
Quote:
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Originally Posted by kirny
no swapping the shift forks will not fix your issue fyi there are only 3 of them also if it is popping out of gear then you are beyond shift forks i only say this because i have seen other people INCLUDING ME tried to just change the forks and it didnt do shit so i took everything apart put it all back together just to take it apart and again.......anyways my suggestion to you is to get a used transmission and just swap out the shafts or get new gears and put them on your old shaft
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You need to split the engine cases and rebuild your trans, replacing the rounded gears and the bent shift forks...And if its really bad your shift drum also in some extreme cases.
Transmission Issue - JohnnyP - 09-18-2012
These are from the last 05/06 trans I rebuilt
This is your problem, notice the rounded edges that are supposed to be sharp
Transmission Issue - kirny - 09-18-2012
Even in those pics it's hard to tell the exct problem I have my old gets sitting in the garage and unless u know what ur looking at most people don't notice the rounding off
Transmission Issue - JohnnyP - 09-20-2012
Quote:
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Originally Posted by kirny
Even in those pics it's hard to tell the exct problem I have my old gets sitting in the garage and unless u know what ur looking at most people don't notice the rounding off
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RED circled area = BAD
GREEN circled area = GOOD and what they should look
