richd3000

At the begining of this summer my 636 would randomly slip outa second gear right at or before rev limiter. It wouldn't do it if I tried to make it, but would randomly when not expecting it. Is it my shift forks or drum, or is it the gear itself worn out? I changed my oil every 1k miles and always use my clutch when changing gears...

smallsgsxr

shift fork for surelies

kimmoke

03-04 636 gearbox proplems too?I tought they were solid.05-06 are known for bad gear sifting and proplems on gear staying in.

richd3000

is this something that could have been avoided by getting one them aftermarket shift stars??? and how bad is changing a shift fork? will i have to split the cases or can i get to em through takin off the oil pan? this brakes my heart! this bike is my baby...

toXic[GSR]

well if you dog boned your shift fork you CAN repair it but yes you will have to crack the case. I had this problem with my bike when I dog boned the shift fork and ended up replacing the whole case, Its alot easier and if you pay for a shop to do it, its cheaper in the long run when you calculate the labor hours. Sorry to hear about it though, I know it sucks.

richd3000

What do u mean by dog bone the shift fork? And I wonder how much a shop would charge if I droped my motor n took it to em? Maybe I should just look for me a new(used) motor off ebay or this site...

swampy

it more or less means you rounded off the end of the fork. trust me getting it fixed is a hell of a lot cheaper then trying to buy a motor. plus i dont think you have to split the case to change out the forks and drum. i have to go down to the shop and look at the motor i got torn apart to make sure of that, but im pretty sure last time me and my buddy did it all we had to do is pop the oil pan off.

richd3000

hell yeah man thanks! yeah that would be sweet! and alot easier. if i had to split it, could i just turn motor upside down and pull case apart with top end intact, or do i have to take the head and cylinders and or pistons off too? if i do have to take it all the way down, should i put new rings on it too? anyone do that?

swampy

sry i forgot to check i will tomarrow and yes you would have to tear the motor completely down in order to split the case. and ring kits tend to be expensive last that i remember and i wouldnt worry about that.

skunkie

it can be done with engine in bike , without splitting cases

http://www.kawiforums.com/how-tos-fa...ing-forks.html

albanyrida

i had the same problem whith my bike costed me around 1600$ to get it fixed and thats whith me takin the motor out and bringing it into the shop

KennyCBR600F3

this is a super easy process!!! you dont need that spanner clutch tool... just use a half inch impact and the proper socket!!!

swampy

you got taken and hard for that

richd3000

Ah, so I am going to pull clutch n oil pan n get them forks n drum out to see what's going on in there. If my gears do show wear, can I just drop motor n flip it upside down n split open the bottom end? I was scared I'd have to take the whole top end apart.. I heard some one say u could flip n split to get tranny out and someone else said I'd have to take top n everything apart.

albanyrida

i was gona do all the work myself but i never had a tranny apart b4 i first noticed somthin wrong sometimes wene id pull it up in 2nd it felt like the chain was jumping on the sproket then by the end of the sumer if u tried to crank it in 2nd it would pop into nuetral

swampy

ok i just went down to my shop and took a look at my torn down motor i was wrong . you are right, you dont have to strip down the whole motor to split the case. just flip it upside down and go at it, but thats only if the gears show a good amount of wear. with the drum and forkes just drop the pan and you have access to them. good luck bud and just remember where all the bolts go and how everything came apart

richd3000

Hell yeah!!! Ok, soon as I get a spot cleared up in my garage ima tear into it. I guess I shouldn't ride it anymore, if it continues to pop out of second it will wear the gears down more right? I will fix this motor n tell yall everything that happened. Thanks a ton for the help and advice yall!