Thanks for the suggestion. I'm thinking I should just send it in and have all gears cut. I'm going to give them a call tomorrow and see if I can send the shift forks in to have them inspect them also. I don't know enough to even identify if there is an issue with them. I can remove bolts all day, but that's where my skills end lol.
When I talked to Smither's he seemed far less than excited to take on the job and it would be 3-4 weeks before he would even have time to look at it. Made my decision to tackle it myself much easier. Let's hope I can get it back together when the time comes!
Thanks for the heads up. I will find the specs and get to measuring.
Looks like the spec is 4.8-4.9mm. My forks are coming in at 4.5-4.7.
If they are not too pricey I would change them all. I saw a guy once tear into his motor (YouTube video) due to losing 6th gear and the fork wear was the problem and wasn’t moving the gear enough to engage the dogs between the two. I remember him emphasizing how important it was to make sure the “C” clips in the end of the shafts were seated properly in their grooves so gears would stay in their position and also making sure the small holes on some of the bearings lined up with the holes on the shaft for proper oil flow. I watched a lot of those videos when I was looking for the answer to my false neutral between 5th and 6th gear, but turned out that Suzuki went from 3 dogs on the gen1 to 5 on the gen2 and makes it harder for the gears to engage when you pin the throttle. @c10 took the time to make some calls and get some expert’s insight on it and shared with us.
I'm going to tear into it further today and get the forks out so I can measure the actual clearance between the fork and gears. I'm thinking about replacing them all with billet forks to hopefully help prevent an issue in the future, but my budget is starting to run thin. It's $108 each for stock forks, or $175 each for billet.
Didn’t expect them to be that much, but Suzuki oem parts seem to be on the high side. Sounds like you are taking the right approach by checking tolerances and just replacing what’s needed to save some $$$
www.partzilla.com
Are you talking about the fork shafts or the actual foot shifter shaft? Why do you suggest I replace this though?U don’t need billet forks. I’d do the shift shafts tho
Suzuki Motorcycle 2006 OEM Parts Diagram for GEAR SHIFTING | Partzilla.com
Buy OEM Parts for Suzuki Motorcycle 2006 GEAR SHIFTING Diagram
Now u know which one u need two of
Ah okay, thanks for the heads up!
Try using a small scraper to get the thick stuff off then use kerosene and a firm paint brush...that should remove it.
Hi. Did you figure out what clutch kit yet? I have over $2,000.00 in my transmission. The bike can make over 800HP. I use the stock clutch kit and DME does too.
Howdy, you quoted me, not the OP
It's more like tar. Very sticky so all dirt and dust just piles up on it.
The scraping part was as far as I made it. Sounds like I have a couple weeks before the transmission will be back so plenty of time.
I went with the Trac King clutch kit. It was the same price as the stock kit so I assumed it was an upgrade. Maybe I was wrong. If so at least I don't have to pull the engine again to swap it out. Thanks for the heads up.
