ra12r
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posted June 23, 2002 12:40 PM
2nd Gear Issues!!
I am currently having an intermitant 2nd gear problem. While doing moderate acceleration in 2nd gear there intermitantly occurs a hard release and instant grab. this usually happens fast enough to not affect the rpms. But, sometimes it will jump up in rpms. It feels like the chain jumps a tooth. I am not sure that it is 2nd cause the bike never jumps out of gear, just jerks like the chain is jumping a tooth on the sprokets. It will not do it everytime and seems to be only 2nd gear dependant. Does anyone have any ideas?!?!?!?!
I have checked the clutch and stuff twice. checked all the teeth, changed chains, change gear sprockets. It does seem to do it more after going around a corner, but is not consistant!
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entropy
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posted June 23, 2002 12:59 PM
ra12r,
I was having the same thing at the drag track. A clanking sort of sound. I thought it was a loose chain but the cahin wasn't loose. It was intermittent, but limited to 2nd gear. This started after about 400 passes of WOT 1-2 shifts (PS3 Dale Walker button shifter).
I just recently had my motor torn down for some upgrades (heh-heh-heh  ), and the builder said that my forks were worn and the drum had a little wear, and he asked me if I was having any 2nd gear problems. The gears are fine but I am replacing the drum and forks (about $250 for parts).
perhaps now is the time for that 1361 or 1270 kit, eh?
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ra12r
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posted June 23, 2002 02:36 PM
yes, i think you are describing the same thing. I do get a second gear shifted without problem whether foot or air shift and i am talking about shifting at 3000rpms into second then rolling into the throttle with the clutch fully engaged,,,,,,then the bike "feels" like the chain jumps a tooth or the clutch lets go and grabs real fast.
I thought it was the chain problem.
But, if it is an imcomplete shift shoudln't it "pop" back out of gear? It never pops of out gear. Just does a quick release and grab?
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entropy
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posted June 23, 2002 03:59 PM
,,,then the bike "feels" like the chain jumps a tooth or the clutch lets go and grabs real fast...
exactly! except mine was doing it at 9-10,000 rpm.
so.... are you gonna pull the motor down to replace $250 worth of trans parts, then "as long as you are in there" do a few grand's worth of essential upgrades?
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ra12r
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posted June 23, 2002 06:53 PM
I went anal this evening and noticed that the sproket i have been using, the teeth are wider than the oem 46 tooth. So I shimmed my sproket over with some washers. After that, I could only get it to do it one time after many tries.........
I was thinking, if your gears are fine, then your gears were not grinding each other. IF your gears are not grinding, then you have not found your problem?!
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ra12r
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posted July 04, 2002 07:19 PM
Sadly, it did NOT fix my jumping problem. This is a strictly 2nd gear event and only under some level of pull. Is there anyone with 2nd gear failure?!?!
My bike is under warranty, but!!!!!!! I don't EVER let anyone touch my bike and the dealer would have to for me to get the warrantied items. My warranty almost has no value at this point..... 
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BA
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posted July 04, 2002 09:21 PM
RA and Entropy, you guys are describing the *EXACT* same problem that happened to the 2000 GSXR 750 when it came out.
They never issued an official recall, but if you took it in and complained, they would fix it free of charge.
Entropy, I was hoping that you'd have had a simpler fix, like the one I'm about to mention they had on the 750, but the next logical step would have been the shift forks so it's not too terribly surprising that your's were worn or bent.
The problem with the 750 was that it would bend some hollow shaft withing the shifting mechanism. Sorry that I can't be sure which particular part it was,...I only know that it was definitely a part of the shifting mechanism, definitely 2nd gear only, definitely fixed with a "solid" piece, and it was only happening on a small number of bikes.
The feeling, and I rode one several times that had the problem was JUST like your sprocket had just jumped a tooth or three. Just like you described.
Good luck in finding the culprit man!
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ra12r
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posted July 05, 2002 10:06 AM
In examining the forks earlier this year, they didn't look like they would bend before they would just break. They seem to be a very hard metal. I am just not wanting to tear the motor down, but it is not looking good!!!
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entropy
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posted July 05, 2002 10:54 AM
the forks wear, at least mine did. Also the dogs on the forks and the gooves on the drum wear just a bit. My motor guy said that's what was causing my popping out/in of 2nd. The amount of wear on the forks, dogd and drum seemed small to me but but I guess that was enough.
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madmike
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posted July 05, 2002 12:41 PM
I noticed a slight amount of wear on my forks, but none on the drum, actually it was more like a small polished speck. so I left it in, but this winter when I tear down again, I will probably replace them. oh motor seems strong we will see this weekend.
Mad Mike..
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ra12r
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posted July 05, 2002 01:34 PM
Entropy, did your builder notice any wear on the gears themselves?!
There are 3 forks if i remember correctly, are you replacing all of them or what?!
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entropy
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posted July 05, 2002 01:43 PM
no wear on the gears, he specifically mentioned that.
As far as the number of forks, I thought there were 2 but that's why HE is building the motor NOT ME, eh?
My bike was doing the 2nd gear ou/in only now & then, and the builder guy said it would have gone alot further without replacing anything, but as long as the motor is in a thousand parts, time to do it.
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madmike
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posted July 05, 2002 01:59 PM
there are 3 forks in there.
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ra12r
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posted July 06, 2002 08:07 PM
I have now found another zx12 2000 with the "SAME" issue in my area. This guy I know does not drag race his bike any......
What is the measurement difference on the newer forks. I bet that they are thicker forks with the drums being the same?!
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ra12r
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posted July 08, 2002 08:33 AM
Entropy, did your guy find any problems with the external shift mechanism?! What exactly did he find?! Is your problem fixed now?!
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entropy
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posted July 08, 2002 08:40 AM
my external shift mechanism is fine. The wear on the internal parts is just a function of many WOT passes, normal wear & tear. When i hit the button on my electric shifter, it shifts HARD; good & hard, not bad & hard.
The motor is still going back together so I won't know the results for a couple of weeks. However, I had it torn down for major motor work, not because of the shifting. My shifting problem was intermittant; one pass out of 20 or so.
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ra12r
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posted July 08, 2002 05:52 PM
Well, after much research I am of the conclusion that it is my dog bones and they need to be repaired. Tranny is going to R&D for work over!!! Thanks for the imput all!
Entropy, i hope that what they are doing to your tranny is enough. I would hate for you to be like me,,,,after 1,200 miles on rebuilt motor.......
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GOZR
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posted July 09, 2002 06:09 AM
Yes it suck..Craaaaackkkk!!!! but i manege 
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