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Sal_the_man, Triple X
Most users ever online was 4,519, September 2, 2015 at 03:26 AM.
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Transmission problems - need input
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  (#1)
2004 R6
 
z06 kos's Avatar
 
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Location: Northern VA
Transmission problems - need input - November 23, 2007, 07:50 PM

Was cruising today at 45mph in 4th gear and all of a sudden it pops out of gear and into neutral.

Attempted to downshift to another gear and also tried upshifting and it stayed in neutral. Drifted to the right lane and into a neighborhood and parked it.

Started it up back up, took like 7+ tries to get it into 1st gear with the clutch fully squeezed...can shift into 2nd but won't go into 3rd, 4th, etc...

Anyone ran into this sort of issue before?
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whoa preppy......
 
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November 23, 2007, 09:49 PM

Popping out of gear is typically indicative of a shift fork being worn to the point of no longer engaging the shift drum.


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  (#3)
whoa preppy......
 
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November 23, 2007, 09:55 PM

see attached


parts = not too expensive.
labor = rape

motor comes out...case have to be split
Attached Images
File Type: jpg shift_cam_fork copy.jpg (94.4 KB, 38 views)


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  (#4)
2004 R6
 
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November 23, 2007, 10:19 PM

thanks Scot, about how much labor time involved?
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whoa preppy......
 
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November 23, 2007, 10:24 PM

*IF* that's what it is, I believe it's about 10-12 labor hours.

If you are somewhat mechanically inclined and can remove the engine yourself, it's probably half or slightly less.

It may be cheaper to go the used engine route.


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November 24, 2007, 01:39 AM

You should try to take it to a shop. They should be able to try to ride it and figure it out pretty quick.


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November 24, 2007, 07:47 AM

There are cams, palls, springs, detents, ... in the linkage that turns the shift drum who's disajustment can cause these symptoms and who's reajustment does not require pulling the motor or splitting the case. It is worth having a shop look at it.
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November 24, 2007, 10:44 AM

yeah sorry to say it sounds like a internal issue.
But before the motor is removed and split its always smart to check the clutch adjustment, linkages and parts you can inspect w/o going into the motor.

Have you ever had any other shifting issues? Once you have damaged something the problems just get worse, but they may start out minor.
By the time you are poping out of gear you have issues, and a bent fork can take out your shift drum and the dogs on the slider gears.

I did the shift forks on my '04 R1. It needed new forks and a shift drum.

Let me know what your plan is. Right now I'm looking for work and doing a few side project sounds better than working at a shop right now.


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November 26, 2007, 12:19 PM

Ok, found the issue,

The tech called and told me it's a spring that connects to the shifting drum or something like that and would involve 2 hours of labor and $7 in parts.

So about $210 total repair bill.

That is acceptable...I was hoping I wouldn't have to shell out $1400 to replace the forks.
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November 26, 2007, 12:52 PM

Quote:
Originally Posted by Dieder
yeah sorry to say it sounds like a internal issue.
But before the motor is removed and split its always smart to check the clutch adjustment, linkages and parts you can inspect w/o going into the motor.

Have you ever had any other shifting issues? Once you have damaged something the problems just get worse, but they may start out minor.
By the time you are poping out of gear you have issues, and a bent fork can take out your shift drum and the dogs on the slider gears.

I did the shift forks on my '04 R1. It needed new forks and a shift drum.

Let me know what your plan is. Right now I'm looking for work and doing a few side project sounds better than working at a shop right now.
That's good advice...have a shop take a look at it. I thought the tranny on my race bike was screwed up and it turned out that the adjustment on my boot wasn't allowing my foot to move enough to shift the bike into gear As soon as I loosened up my boot everything was fine. Hopefully, it's an adjustment issue.


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whoa preppy......
 
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November 26, 2007, 04:10 PM

Quote:
Originally Posted by z06 kos
Ok, found the issue,

The tech called and told me it's a spring that connects to the shifting drum or something like that and would involve 2 hours of labor and $7 in parts.

So about $210 total repair bill.

That is acceptable...I was hoping I wouldn't have to shell out $1400 to replace the forks.
Was it the detent spring? If so, 2 hours is about right. If memory serves correctly, you remove the clutch cover, clutches/plates, basket, and maybe the gear for the oil pump. It's easy as hell to install, just a bit of work to get to. I've done two in Yamahas in the past.

In my picture above, the dentent spring keeps tension on the detent arm. The arm rests in the notches of the star shaped piece at the end of the drum. (6 pointed star...oye!)


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November 27, 2007, 07:08 AM

where did you take it to get looked at, im starting to have a similar problem

Quote:
Originally Posted by z06 kos
Ok, found the issue,

The tech called and told me it's a spring that connects to the shifting drum or something like that and would involve 2 hours of labor and $7 in parts.

So about $210 total repair bill.

That is acceptable...I was hoping I wouldn't have to shell out $1400 to replace the forks.
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  (#13)
2004 R6
 
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November 28, 2007, 06:58 PM

went to the shop today, they gave me the broken spring...heh



new spring comes in Friday and bike should be out Monday.
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