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Discussion Starter #1
I just bought a 95 zx-6 from a private ad, and the guy says that I need to replace the 2nd gear fork, he says all the other gear forks have been replaced... well my question is what the heck is a gear fork, I have never heard of it, and I can't seem to find any info...Does he mean like the 2nd gear shaft? He says it's too big and it will slip out of 2nd gear... I am new to bikes so any help would be appreciated.
 

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Umm, is this a ZX-6E? If so, it probably needs more than just a shift fork. See www.zx6e.com for more information. I have a 94 and decided to replace the engine with a much newer one instead of fixing the current one. Anyway, it's a lot of work. The engine must be removed from the frame, and the case split to get at the trans. Again, see the zx6e site for more information (assuming you have a ZX-6E and not a ZX-6R)
 

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i really hope you got the bike cheap cause the problem you have is gonna be $$$$$$$$$$. he was talking about the SHIFT FORK which means engine removal,case splitting etc. LOTS AND LOTS of work for the SHOP since you are new to bikes. :(
 

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Discussion Starter #5
Well I did get it for a good deal, how much do you think the shop will charge me? It's just the replacement of the 2nd gear shift fork....www.zx6e actually had a link to a tutorial on how do it so maybe if its too pricey by the shop I will ask a friend who is bike savey to help me out...
 

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Winter

As long as you have a nice warm shop and you have lots of time and a digital camera and take real good notes...you might save some money. Shifting from first into second really puts a load on second gear...most everyone thinks winding out firs then slamming second is the right/cool thing to do, when actually all the shifts should be smooth...at least the first two or three. Second gets slammed all the time...that is why the forks get bent inside the tranny...good luck...keep the forum up to date and it wouldn't hurt if you sent some pictures to us...it would be cool for some of us to follow...some could care less...they live in warmer climates and ride ALL of the time...I won't mention FL, LA, TX, NM. AZ. CA. and several other states...but they know...people in MN, WI...perhaps thay are into snowmobiles at speeds greater tahn what our maximum Speed LIMITs are on federal Highways...but good fo rthem...they can always read up and catch up when they are defrosting,,,or maybe their girlfriends can teach them a thing oro two about their bikes...don't know about the northern girls, never slowed down long enough on my bike or rode in really bad weather long enough to find out...Perhaps this is something that will come OUT of the Ladies Only Forum for us...???
 

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Discussion Starter #8
Out of curiousity what will the shop charge me for this... 500 sounds realisitic or is it way more???
 

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jenya said:
Out of curiousity what will the shop charge me for this... 500 sounds realisitic or is it way more???
Sorry, but a shop would charge way more than that. You would save some money if you removed the engine yourself. The parts alone are $300 or so (if you replace everything shown on that link)

Another option is to find a newer engine on Ebay and swap it yourself... that's what I'm doing. I found an 03 ZZR600 motor (same bike) for $620 shipped, and another person on the zx6e forum recently got an 04 motor for $700 or so I think.

I would NOT recommend buying an older ZX-6E motor because there's a good chance that second would be messed up on that one too.
 

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Discussion Starter #10
According to the seller it's just one of the shift forks that need to get replaced, I see it only for like 55 dollars online. I guess the best thing will be to take it to the shop let them give me an estimate. Who knows what else could be wrong with it :?
 

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jenya said:
According to the seller it's just one of the shift forks that need to get replaced, I see it only for like 55 dollars online.
Has he actually cracked the case to look at it? If so, why didn't he replace a $55.00 part? How does he know that it's the only problem?

If you ask around to other ZX6E owners on the forum I referenced, you'll find that the shift drum and gear dogs are usually worn as well. You won't know for sure until you crack the case and look at it. If you find that the shift drum and gear dogs are bad like the guy did in that tutorial, it's over $300.00 in parts(using pricing from Ronayers.com).
 

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Discussion Starter #12
Well, what he was saying is that all of the forks, and the drum had been replaced, but one of the forks installed was the wrong size which causes it to slip. In any case you are right, I have no assurance of that so thats why i am going to take it in for an estimate. I mean he says that the bike is rideable in it's condition now, but I am sure the wrong sized fork will cause a lot of damage...

Quick update:

I got quoted at 825 to do it at a near by shop...
 
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