99-02 R6 ONLY 2nd gear slippage problems - warranty issues

<!--EZCODE BOLD START--> mggspeed<!--EZCODE BOLD END-->, I added your name to the list. I'll send you an email as well.

-Ariah

Hi All.. Just poking my nose in here. I have an older Kawasaki ZZR1100. The C1&C2 Models of the ZZR had this problem as well. 2nd gear failure at around 19K Miles. Kawssaki replaced the gear in the D models with one that was slightly undercut - Simple design flaw - They built the engine too strong for the gearbox ( 2nd gear ). Not much could be done. Drop the engine replace the gear with an undercut one.

Thanks for the input Graham.
At least Kawasaki changed their design.....
Yamaha have stuck with this tranny and have no intention of changing from what their warranty manager was saying. Pardon my ignorance, but what is an undercut gear?
The ZZR problem seemed to kick in a fair bit later than the R6, so I am assuming that it was not covered by warranty either.
At least Kawasaki had the balls to admit a design issue (because they changed the design), unlike Yamaha who are too stubburn to admit the truth, instead insisting that we are all incompetent riders.
ARRGGHH - I get angry just thinking about it!!!

In response to Ara Tidwell's previous post, here are the gear ratios for some bikes in the same class as the R6:

<!--EZCODE BOLD START--> 2001 GSXR 600:<!--EZCODE BOLD END-->

1st 2.785 * * * * * * * * * * * * * * * *
2nd 2.000
3rd 1.600
4th 1.363
5th 1.208 * * * * * * * *
6th 1.086 * * * * * * * * * * * *

<!--EZCODE BOLD START--> 2001 CBR F4i:<!--EZCODE BOLD END-->

1st 2.833
2nd 2.062
3rd 1.647
4th 1.421
5th 1.272
6th 1.173

<!--EZCODE BOLD START--> 2001 YZF R6:<!--EZCODE BOLD END-->

1st 2.846
2nd 1.947
3rd 1.556
4th 1.333
5th 1.190
6th 1.083

Ara is right that the R6 has the largest gap between 1st and 2nd gears. However, I don't see what the 15,500 RPM rev-limit has to do with it, as all the other gears are spaced within the same range as the Honda and the Suzuki. If the higher rev-limit of the R6 was the reason for the larger gap between 1st and 2nd, the same would hold true for the rest of the gears. -Meaning all the other gears (2nd through 6th) would have a larger gap as well, which they don't.

The relatively large gap between 1st and 2nd gears may be partailly responsible for the transmission failures, but that doesn't automaticly make the rider responsible for the failure because he doesn't know how to shift a "wide ratio" transmission properly. If there were really such a difference between the riding technique of an R6 vs. and F4i or Gixxer600, I think it would be widespread information.

I have a 2000 with roughly 11,000 miles on her and am also losing 2nd gear.... I have taken very good care of this bike and have never really beaten the piss out of her... I ride it like a sportbike should be ridden.... I hate to say it, I love the bike but this problem has definitely influenced what I will purchase next... It wont be a Yamaha. I have had two CBR's in my family with high milage and I have never experienced any problems like this before. I was quoted a repair cost of $2,000.00 - which is money I don not have - I am so disgusted right now - The damn bike is in the garage coverd up - I still have not decided what to do with it.
My bitch is done...
Long Time Member - Eric

Alright, no more 2nd gear clutching wheelies for me! My 6 just passed 11K Miles and still strong, but this topic scares the piss out of me, more then a head shake. From now on it just smoooth ridding.

Ariah, the 1st to 2nd shift is the largest gearing gap on any bike and has the least "overlap". This is why the other gears don't go like second. Also ever notice how it is harder to shift at redline vs say 12 or 13k? I guess you can call it a design flaw, I'm no engineer but I'm not really sure if there's a pratical way to keep the second gear more resistant to wear with current generation technology. What I'm trying to say is the R6 tranny in its self is no different than any other bike, but it just gets put under a higher strain because of the ratios and the high rev motor.

After I blew the first tranny (not literally..) I started being real concise about my 1-2 shifting (always pulling clutch in to grip and making quick smooth well timed shifts) and that rebuilt tranny lasted for over 20,000 miles of "very hard riding".

I don't mean to sound like an dick, but these things ain't luxury sedans, their high performance race motorcycles being sold as street legal. If you want a half assed bike buy a Honda VFR. (a great bike for what its made for)... If you want the ultimate canyon carver and are willing to put up with the troubles that come along with the performance, get a R6... but I would point out most riders don't ride 20,000+ miles a year. I'll bet the average life of a R6 is well under 10K miles.

Last word of advice if you want your R6 second gear to last... Try to avoid first gear use. Keep it in second whenever possible and try to make the shifts between 1-2 at low speeds. And don't clutch up wheelies!

Ara, my point is that, as you stated, the R6 is no luxury sedan. It is indeed a race bike sold for street use. However, so are Gixxers, CBRs and Ninjas, and I don't see any of these problems with their transmissions. These are all high performance machines designed to easily take the abuse of your average Joe Wannabe Street Racer.

As for putting up with the troubles that come with performance, I didn't pay over $8,000 for a vehicle that is going to have major internal failures within 20,000 miles. And the average life of the R6 is still rising. Hell, it only came out in '99, wait 5 more years and I'm sure the average mileage R6 will be that much higher.

Anyway, it seems like your trying to find reasons why it should not be covered under warranty, which is really the point of all this. I'm trying to make it so we don't have to argue about having repairs done, like I'm doing here. Maybe you should get a job with Yamaha's Warranty Dept, it sounds like you already have your mind made up that these failures are all rider induced and have nothing to do with a faulty product. >:

I've had that same problem, I replaced my motor with a new one! Anyway, e-mail me with any info you have..
brc_nnc@yahoo.com I would love to see what you all have got!
Later

Thanks Brian, I'm in the process of getting together everyone's information right now.

In the meantime, here is the latest list:
Also, everone please check out this poll: Click Here - R6 Transmission Poll

<!--EZCODE BOLD START--> CtryBoyInMT
draughtr6
yam99blue
Rsicx
mullerr666
Hpower281
yzfman
Duffster
R6 on one
92GTstang
HDs99
ChiTownR6
r6HeavenTNT
Jdubb431
prv8pilot
idroppedit
dtorok84
Eric01
R roku
baw02141
RuiTrigo
Greg2k1R6
Wheelie Monster
drspeedmore
r6danger
Jon AKA Spike
nailed
Suomy
mggspeed
Eric01
tricksix
rustyph
topherwilliams
R6Sin<!--EZCODE BOLD END-->