Stuart Racing
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posted August 29, 2007 06:24 AM
Changing shift forks...
How hard or easy is it to change out the shift forks on my 02 zx12r....I read the manual and looks pretty straight forward...Any tricks or advise from anyone????
Thanks,
Paul........
  
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madmike
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posted August 29, 2007 07:05 AM
I have only done it when the motor was completely dissasembled, But from what I have been told and seen, it looks very simple and you just have to drop the pan...
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Stuart Racing
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posted August 29, 2007 10:12 AM
Thanks Mike...Looks sorta like a KZ motor to change the forks...With an auto trans. in my dragbike,i'm kinda used to changing shift forks....Anyone got a spare set of forks they want to sell?????Just the 2 small ones,not the one on the drum...
Paul........
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nox
Needs a job
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posted August 29, 2007 01:04 PM
Usually, if someone has a set, it is cause they are bent.......
Paul, just to be safe, I would just go out and get a new set........
Whats wrong with it anyway?
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Stuart Racing
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posted August 29, 2007 01:13 PM
 Edited By: Stuart Racing on 29 Aug 2007 14:21
Ya I know,you never know who has a new set they never used...I've learned from my other bike to just get new ones...I got a bucket full of bent ones,don't need anymore,LOL....Thanks though...Anybody got a price off hand for a new set or per fork???
P........
P.S.
My wife and I are going out to TnTune tonight...She is riding my cartire bike(NOS)..Her fastest so far is 8.625@159mph,with lots of tire shake...Gotta tune that out so she can get more ET.It's about 100 dergees right now,(5:20pm)....This is only her 10 or so time on the bike...Gradually putting more NOS as she feels more comfortable with the bike...
See ya,
P......
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ninja12
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posted August 29, 2007 01:19 PM
Oil Pan and Clutch Basket must be removed.
unbolt and slide the shift rods out ,
forks comes out the bottom.
A little tricky to get the fork positioned right, but not hard.
You can pull the motor but still have to pull pan and basket,
just easier to see how to aling the forks on reassembly.
I agree with Nox, get new, They are a wear items IMO.
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Stuart Racing
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posted August 29, 2007 01:23 PM
Why the basket??????
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Stuart Racing
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posted August 29, 2007 01:23 PM
Edited By: Stuart Racing on 29 Aug 2007 14:24
Why the basket??????
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oof440
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posted August 29, 2007 04:02 PM
The basket has to come out so that the shafts that the forks are on can be slid out the clutch side of the cases.
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aliveagain
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posted August 29, 2007 05:12 PM
About $180 for the three.
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Stuart Racing
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posted August 29, 2007 05:54 PM
Edited By: Stuart Racing on 29 Aug 2007 18:57
quote:
About $180 for the three.[/quote
WOW........Gotta do what ya gotta do...Much appreciated..
P.......
If I use the airshifter around town it doesn't come outta gear..But if I foot shift it around town,it comes out sometimes...Dosen't come out at all at the track though...When it comes out it does it on the 1 to 2 shift... ANY thoughts.???
P......
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nox
Needs a job
PMRA / TMRC Super Street 4022
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posted August 29, 2007 07:15 PM
You should see my old second gear, 12 trannys suck........
call mark at rnd and he may be able to diagnos for you.........
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42 Wins
21 Runner-ups
2010 TMRC Super Street Points Champion
2010 PMRA Super Street #3 Points
2009 PMRA Super Street Points Runner-Up
6 Time Centerville Dragway Points Champion
Sponsored by:
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Galfer Braking
AMSOIL
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Kawasaki Sports Center
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Conway Cycle
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Stuart Racing
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posted August 30, 2007 05:25 AM
Ya I here ya...I only use R& D for my tranny work...
Thanks..
P........
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ninja12
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posted August 30, 2007 07:16 AM
quote:
The basket has to come out so that the shafts that the forks are on can be slid out the clutch side of the cases.
He's right. The Only way to get the shift fork out is to remove the basket.
You can split the cases and pull the trans, and basket as one piece.
The shift forks slid on a shift rod approx 5" long. The shifts rods(2) enter the cases
behind the basket , and have a slot on one end to hold them in place.
Once you get the basket out , the shifter shaft ( same one the foot shift lever attaches)
slides out clutch hole then 1 10mm bolt holds the shift rod retainer.
It's not hard work, but it takes a little time pulling parts.
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Stuart Racing
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posted August 30, 2007 08:45 AM
quote:
quote:
The basket has to come out so that the shafts that the forks are on can be slid out the clutch side of the cases.
He's right. The Only way to get the shift fork out is to remove the basket.
You can split the cases and pull the trans, and basket as one piece.
The shift forks slid on a shift rod approx 5" long. The shifts rods(2) enter the cases
behind the basket , and have a slot on one end to hold them in place.
Once you get the basket out , the shifter shaft ( same one the foot shift lever attaches)
slides out clutch hole then 1 10mm bolt holds the shift rod retainer.
It's not hard work, but it takes a little time pulling parts.
Thanks NINJA,
I appreciate the info..The manual dosen't give a lot of info on this...
Thanks alot,
P......
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ninja12
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posted August 31, 2007 10:42 AM
My affair with THIS bike has been waaaaaaaaaaaaaaaaay too intimate. LOL
Glad I could be of service.
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Stuart Racing
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posted August 31, 2007 01:15 PM
Does anything have to come off the left side of the bike at all(shift linkage ,ect.ect.ect....)...
LOL....Just keep your HANDS off my bike...She's a one man bike, kinda bike...lol...
Thanks dude,
Paul.....
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Wolf Racing
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posted August 31, 2007 01:33 PM
Heel, some must be hard on gear! We've got five ZX12Rs running and the Pro Bike is the only one that we have shift fork problems. And, that's only when we do something out of our practices.
Some tips (that I'm sure can be argued) that we have learnt to help save shift forks.
- Run through the gears at low speed (in pits) if the bike has been sitting for an extended period of time. I mean days to weeks. Get lube on the forks.
- Don't rock the bike forward when selecting gears. This is in the burnout or pits. It CAN put undue pressure on the forks.
- After the burnout, stop the bike and rock backwards to get first. Don't rattle your fott on the gear lever as the bike is running forward as you move out of the burnout.
- When you go to select your burnout gear (we recommend third on a standard box), engage each gear prior to selecting the next gear. Just move the clutch lever out and let the gear take up.
- When you stage, stage with the Clutch. This will make sure first is properly selected each time and the dogs are engaged. Forks are set.
We certainly extended life of the forks and tranny ingenerla with these things.
Just from our experiences.
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Stuart Racing
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posted August 31, 2007 01:44 PM
Edited By: Stuart Racing on 31 Aug 2007 14:48
Thanks Wolf,great stuff..Thats exactly what I do with my KZ dragbike with auto tranny...I'm not 100% sure that I have a shift fork problem YET.....I changed oil yesterday and adjusted my shifter pedal ...I had to lower it,(size13 shoe) so I have to get my foot in there just right to change gears....Plus I have a patially fused left ankle from an accident...Really hard tp get a good pull up on the lever(for me)...I used to reverse my lever to push down to shift up...Helped out ALOT....
Anyways I haven't miss second gear all yesterday and today....So maybe it was my technique..
Thanks again Wolf.........
Paul........
P.S.
We used to roll backwards to try to straighten a bent fork in an emergency situation during a race...(for auto trans.)...Seemed to work temporarily....But had to change forks eventually...Don't know if it would help on a streetbike though...
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ninja12
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posted September 02, 2007 08:55 AM
quote:
Does anything have to come off the left side of the bike at all(shift linkage ,ect.ect.ect....)...
LOL....Just keep your HANDS off my bike...She's a one man bike, kinda bike...lol...
Thanks dude,
Paul.....
yes the shifter linkage has to come off. just the one 10mm bolt , so that shaft can go threw the cases. Sounds like you're getting ready to actually do this. 
Keep up posted.
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Stuart Racing
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posted September 02, 2007 12:58 PM
Not totally convinced that the forks are the problem yet...A little more diagnostic work first before I tear it down...But I'll keep ya posted..Thanks for the info...6mm bolt or 10mm wrench????
Paul......
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ninja12
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posted September 02, 2007 02:22 PM
10mm bolt holds linkage to the shift shaft.
It will be obvious when you try to pull the shat out.
What problems are you having with the trans?
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Stuart Racing
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posted September 02, 2007 03:05 PM
Comes out of second gear at gear change every now and then(1 to 2 shift)....I have a patially fused left ankle,hard to lift up for gear changes...I re andjusted the shift lever and hasn't missed a shift yet...So I'm still trouble shootin it to make sure that it HAS a problem...I used to reverse shift my bikes to cure this problem(1 up , 4 down)....
Thats it....
P.........
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Nukedog
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posted September 05, 2007 06:15 PM
2nd gear may need back cut. Was a common problem with mid 90's ZX's and Busa's too...
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ninja12
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posted September 06, 2007 04:14 AM
forks will fix it, maybe only tempary.
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