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03 zx6rr trans repair

1342 Views 13 Replies 3 Participants Last post by  jowek70, 
J
3
Good morning,

This past June, I lost 3rd gear on my zx6rr track bike at Road America. Shifts through all the gears fine, but downshifting into 3rd it flops in and out of gear. Found a low mileage, used trans set up (forks, shafts, drum, gears, etc) for $120 to swap out. My bike has around 14k on it.
I'm planning on a new clutch (it started slipping a couple track days prior), the trans swap, new gaskets, etc, but wondering if theres anything else i should do while inside? Crank bearings, piston rings, etc?
I'm hoping to wrap this up over the winter, so plenty of time but not wanting to drop $2k on a 20 year old bike.
appreciate the input.

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ninjanut
Personally, unless you have engine issues, I would leave it be. Maybe check compression and follow it up with a leak down test to verify the condition of the motor.
Does the RR have a close ratio transmission or is it the same as the 6R?
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J
RR has taller gears.
If i split the cases, will that jeopardize the crank bearings? Engine performs very well, made 112whp on pump gas with bolt-ons and a tune on the kit ECU.
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ninjanut
As long as you are careful and clean, the bearings will not be an issue. Split the cases, repair transmission, put some oil on the crank journals and reassemble.
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J
So far i'm in about $430; thats gaskets, clutch kit and transmission parts.
lets hope the procedure goes well.
Pulling the engine next week.
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J
Finally pulled the engine last night, boy that sucker is light!
New trans parts look great, hoping the swap goes well.
Going to have the valves checked before i pop the engine back in the frame and then i made a list of a few things to do while the bikes torn apart.
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92Ninjas
Pics if you have the time and remember plz
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J
92Ninjas said:
Pics if you have the time and remember plz
Click to expand...
anything in particular?
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92Ninjas
jowek70 said:
anything in particular?
Click to expand...
Just the general process of your repair
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J
sounds good, i usually take photos of the trans before i touch it so i can reference later to assemble.
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J
I ended up dropping all the stuff at my engine guy to do the work. expected back sometime in June, no rush, track day in July. He's going to swap the gears, replace the gaskets and do a valve clearance check.
once i have it back, i will do the new clutch and APE manual CCT.
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J
Engine is done; $300 for trans repair and valve clearance check/adjustment.
Hoping to get it back together this month yet but still need a few more parts for the clutch.
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92Ninjas
jowek70 said:
Engine is done; $300 for trans repair and valve clearance check/adjustment.
Hoping to get it back together this month yet but still need a few more parts for the clutch.
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W00T! I bet you're anxious to get it back on the road!
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J
92Ninjas said:
W00T! I bet you're anxious to get it back on the road!
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Ya i was hoping to do a track day at Road America next month, might have to wait for July now.
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