PERMANENT FIX FOR 99-02 TRANSMISSION FAILURE

[Azr6]

Originally Posted by forumsearcher

I purchsed my bike with the 2nd gear problem... It cost me $100 to fix my 2nd gear, and a day of work... I would rather fix the gears a few times than go and spend $1300. Hopefully I am a better shifter than the first owner.

Howd you fix it for so cheap?

[Johns02R6]

Ok I just checked back here and I can't believe the response it got. Everybody knows that the newer tranny is better (03-05). The extra dog and the bigger shift fork (for 2nd gear) really do make a big difference in wear resistance and strength. I wouldn't make the swap unless the bike was already jumping out of gear though.
Thrak is not correct regarding when the problem occurs. Obviously poor shifts will make it fail prematurely, but the dogs and windows will simply wear over time even with perfect shifts due to the nature of the design. So just because the tranny works fine now, that doesn't mean it won't start slipping tommorrow. It's obvious that not all the 99-02 R6's have had the problem yet, which makes some people think that since they haven't had the problem yet, everyone else must just be an idiot. Give it time and it will fail. The harder you beat it, and the more you use it, the sooner it will fail. Riding 24K track miles doesn't mean crap because you aren't shifting from 1st to 2nd out on the track. 24K miles of stop-and-go in town abuse is MUCH different. So don't let mileage numbers fool you.
I just posted this to help people fix the problem once their bike fails. Our local sprint car shop up the street has R6 motors putting down 120+rwhp on alcohol. He is using STOCK 03-05 trannys (1st and 2nd gear only), and has never had a problem with them failing. He doesn't even undercut them. He did tell me that he doesn't like to use the earlier trannys because even with an airshifter (for perfect shifts) on the karts, the 2nd gear fails rather quickly. Undercutting does help, but he still prefers to use the newer parts.

PS: to fix your own tranny for $100, take it apart yourself, take 2nd gear wheel and 6th gear pinion to a machine shop and have them undercut at 5 degrees. Then reinstall the parts yourself and enjoy your tranny that doesn't jump out of 2nd. It won't be near as smooth or able to handle as much power as the newer trans, but at least it will work.

[blackonwhite99r6]

how much does is the raw parts cost of an 03 tranny with self installation?

[Rob Sherman]

Originally Posted by blackonwhite99r6

how much does is the raw parts cost of an 03 tranny with self installation?

http://www.mrcycles.com/

Installation would depend on who you have do it... $1000??

[blackonwhite99r6]

803 dollars for all the parts on the 03 tranmission fiche from mrcycles. If they transmissions are compatible could you just use the 03 gears with other 02 parts?

[Rory]

What is GP shift style and how does it help shift smoother? I've reamed out first gear and shifted to second and there was grinding in the shift, but I never understood what I did wrong to cause this. Where is there technique in shifting (excluding feathering out the clutch) it's as simple as go - pull clutch - click shifter - feather clutch out. Where did I go wrong?

[blackonwhite99r6]

With a quick revving engine like the 600s in all motorcycles the rpms drop very quickly. If you are moving and you are trying to click it into 2nd gear it will click in harder if the rpms arent close to matched with your speed. In other words, shift before the engine rpms drop down and you wont have as much of a problem. so it should be like, braaaaaaaaaaa-shift-braaaaaaaaaaa not braaaaaaa-aaaa-shift-braaaa...get what Im saying?

[Rory]

perfectly clear, thanks

[Thrak]

Originally Posted by Johns02R6

Thrak is not correct regarding when the problem occurs. Obviously poor shifts will make it fail prematurely, but the dogs and windows will simply wear over time even with perfect shifts due to the nature of the design.

whatever dude... I've had 4 99-02 R6s.

1 99
1 01
2 02's

the 02s were street only, and had TONS of miles... stop-and-go Atlanta traffic miles. I've never had a 2nd gear problem. Period.

You mis-shift, or try to jam it, and you're gonna get the problem. If its a desing flaw, as you say, every 99-02 R6 would have the problem, and they dont.

[jlsparky7]

Can you use the 03 gears on the 02 tranny?