2nd gear problems
Well I'm not sure about your year of bike, but the 05-06's do not have syncro's. In fact I have never seen syncro's in any bike. The gears simply have what are called dogs. They are lugs the protrude from the side of a gear, and lock into the gear next to them when slid by the shift fork. The fork rides on a rail. The fork is slid side to side via the shift drum. When you have a gear that pops out, it's one of two problems. Either the gear is not being slid far enough into the mating gear, or the dogs are damaged (rounded of usually). The drum RARELY fails. The shift forks are made out of aluminum on most bikes. The rest of the transmission components are made of steel/iron. The forks can be bent if a person is hard on the shifter. (Downshifting without a clutch is the worst!) The rails that the forks ride on are hardend steel. They are not very long (about 5 inches) so they are not prone to bending easily. There really is no way of knowing which item is damaged until she is opened up. (not for the faint of heart or the inexperienced.) But if you do decide to tackle it, do yourself a hugh favor...Buy a factory service manual. You can get them on CD now for as low as $10. I finished going through my transmission last night due to damaged dogs. (Previous owner) Hope this helps. And if anyone needs help with their 05-06 ZX6R, let me know.
Well I'm not sure about your year of bike, but the 05-06's do not have syncro's. In fact I have never seen syncro's in any bike. The gears simply have what are called dogs. They are lugs the protrude from the side of a gear, and lock into the gear next to them when slid by the shift fork. The fork rides on a rail. The fork is slid side to side via the shift drum. When you have a gear that pops out, it's one of two problems. Either the gear is not being slid far enough into the mating gear, or the dogs are damaged (rounded of usually). The drum RARELY fails. The shift forks are made out of aluminum on most bikes. The rest of the transmission components are made of steel/iron. The forks can be bent if a person is hard on the shifter. (Downshifting without a clutch is the worst!) The rails that the forks ride on are hardend steel. They are not very long (about 5 inches) so they are not prone to bending easily. There really is no way of knowing which item is damaged until she is opened up. (not for the faint of heart or the inexperienced.) But if you do decide to tackle it, do yourself a hugh favor...Buy a factory service manual. You can get them on CD now for as low as $10. I finished going through my transmission last night due to damaged dogs. (Previous owner) Hope this helps. And if anyone needs help with their 05-06 ZX6R, let me know.
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