Replacing shift fork (help)

[Blake051300]

I found a killer deal on an 05 Busa after being without for over 5 years. I picked up mine for $3800 knowing that it occasionally pops out of second gear. From what I know this is a fairly common problem that is usually caused by a bad shift fork. A friend of mine builds engines and is more than capable of doing the fork replacement but he is really busy building engines for the coming race season. I am hopeful that the weather will change soon and I can ride. I already have the engine pulled and ready for him to tell me to bring it by, but was wondering if this might be something I could tackle. Maybe someone can give me a heads up on just how difficult the job would be. I would probably pay him only a couple hundred to fix and really cant afford to pay what the repair would actually cost. ???

 

[HAYABUSA1340]

Its from shifting w/o a clutch

 

[turbobusa2000]

Depends on what your mechanical ability is. Do a search for permanent shop manual and see if it looks like something you could tackle.

By the way, coming out of second gear doesn't necessarily mean its a bad shift fork, it could be. However my I would guess that the dogs on the gears are worn, which would require replacement gears or a reweld and back cut.

 

[Blake051300]

I've done some checking and it appears that the cases need to be split. I've put together small block car engines but not to sure I would feel confident doing this one. Guess I better just except that I need to wait on my friend or start gathering some quotes from other people or repair shops capable of making the repair.

 

[mike04busa]

It's not as bad as you think. Get a repair manual and it's just taking the lower case off. The only thing you have to watch out for putting it together is the lower timing chain guide.

 

[Blake051300]

I'm trying to locate a service manual that I can download. I started a new thread hopefully someone will help me out.

 

[dabeechman]

You should just get the manual. It is worth the 20 bucks to have it on your bench to flip through when you need to check specs or tolerances.

You will obviously need to split the cases. It is not an easy job and a simple mistake will cause a catastrophic failure. I don't know your mechanical prowess, but it isn't something you should tackle if you have never been inside one of these motors.

 

[BlueHaya]

the online book is nice to have, but a paperback on your bench is hard to beat. I have the Clymer. Check around for prices.


Clymer Suzuki GSX1300R Hayabusa 1999-2007

 

[Blake051300]

I'm thinking I should just wait to have it done by an experienced mechanic. A friend of mine has a cylinder and +2mm piston set plus cams laying around, I may just be real patient and try to get it all done at one time. Not sure, but man I wanna ride..

 

[GPW]

hmmm...this is a Gen I correct. If you brought me the motor out of the bike. I could handle the job for a fair price and I could teach how to do it yourself, using just the manual. I am still learning but watching a program today which discussed an acceleration gift God gives to certain people. It did sum up to mean, if you are in his graces he will cut down 30 years of experience in just 72 hours...three days. Its my only explaination to my growth. LMK.

 

[Wag]

Its from shifting w/o a clutch

Maybe from shifting BADLY without a clutch!

BTW, get the manual and do the work on your own. If you have reasonably decent mech skills, you should be good to go.

--Wag--

 

[mike1180]

hmmm...this is a Gen I correct. If you brought me the motor out of the bike. I could handle the job for a fair price and I could teach how to do it yourself, using just the manual. I am still learning but watching a program today which discussed an acceleration gift God gives to certain people. It did sum up to mean, if you are in his graces he will cut down 30 years of experience in just 72 hours...three days. Its my only explaination to my growth. LMK.

Sounds like a good program.
Do you remember the name of it?

 

[Blake051300]

GPW I'll send you a pm, if you raced Mirock we probably know the same people.