Anyone here swapped a trans in a 636? I have heard 05 and 06 are the same. 2nd gear is gone on my friend's and he is a broke *** so I will be changing it for him. Anyone ever done it that I could talk to? It looks obviously like you need to drop the motor out of the bike, turn it over, and remove lower case half, but would like to know a bit more about this before I go tearing into it. Any help is appreciated. thanks-John

 

not 100% sure on whethe it's the same trans, but i can offer advice in this..

yes, the motor has to come out, but theres no need to invert. if anything, leave the motr upright. the shift drum and all will be in the lower case..

also, DO NOT replace just the blown gear. replace BOTH the driver and driven gear as a pair. those things wear in as a set and will conform to each other.. if you throw in an alien gear, the wear pattern across the tooth face will differ and wear abnormlly sometimes.. riding style affects this pattern and slope.. and no two ppl ride the same.. every gear wears differently.. 2nd is the most susceptable to blowing, so this is cerainly a case where you'll wanna replace a pair instead of an individual..

i mean, do what ya want.. lol.. i know guys who replace just one gear, but oft times it seems they call me up in a few weeks or so wondering why they lost 2nd gear again..lol

so..
-get a manual for torque specs (if you don't have one already)
-all the appropriate tools (torque wrench and misc tools)
-a nice work area.. clean and level..
a caliper or outside mic set (for spec-ing the fork tang wear and everything else.. you might as well.. you're gonna be *****-deep in it. check the valves and all the clearances while you still can..)
-get all the gaskets

can't think of aything else, really.. just take your time and be organized. it'll go well.
we're here for ya every step of the way!

oh, and welcome to KF!!!!!

 

05-06 636's have the same gears. And do what whitehendrix said. Download the manual off the net; here http://www.manualz.info/