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Old 02-01-2009, 05:57 PM   #21
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Old 02-01-2009, 06:12 PM   #22
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Hmm, well I found some wear on the 3rdand4th gear input. There's 83 bucks right there

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Old 02-01-2009, 06:35 PM   #23
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Ok I found where all the NOTICEABLE wear is. Can't capture the pic cause its still in once piece but this is basically what it looks like. The one on the left is the output 2nd gear. I colored the left side but just flip it and thats what it looks like. The part on the right is the output top gear.

5l6ngw
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Old 02-01-2009, 06:48 PM   #24
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Here's the little slot where the shift fork goes. The other two aren't worn like this one is.

2nhkqw7
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Old 02-01-2009, 06:56 PM   #25
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Old 02-01-2009, 07:12 PM   #26
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Quote:
Originally Posted by ford View Post
why don't you take it to patrick at Motorcycles Unlimited and let him fix it
Because my labor is free and I have the time I got a service manual and more than enough online support from people who have done this same exact rebuild before. Thanks though. I'm learning alot about bikes as well
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Old 02-01-2009, 07:30 PM   #27
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Old 02-01-2009, 08:45 PM   #28
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Quote:
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HA! So it was your fault!!

Kinda a die hard, but whatever proves itself to be the best and most reliable, I'll get it for the track.
uhhh....KINDA????? he's like every kawi owner out there...cant tell em nothin....kawi this and kawi that...kawi kawi kawi blah blah blaaaaah
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Old 02-01-2009, 10:34 PM   #29
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Quote:
Originally Posted by gixxergirloh2 View Post
uhhh....KINDA????? he's like every kawi owner out there...cant tell em nothin....kawi this and kawi that...kawi kawi kawi blah blah blaaaaah
truer words where never spoken

fuggin kawis
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Old 02-02-2009, 12:22 AM   #30
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Quote:
Originally Posted by gixxergirloh2 View Post
uhhh....KINDA????? he's like every kawi owner out there...cant tell em nothin....kawi this and kawi that...kawi kawi kawi blah blah blaaaaah
Quote:
Originally Posted by Romeo36 View Post
truer words where never spoken

fuggin kawis

Quiet. . . the both of ya.
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Old 02-08-2009, 01:47 PM   #31
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Ok well Grinchy came by Sat afternoon and we (he) removed some gears off the shaft and we inspected the gears.
BTW thanks mate!

I don't know too much about transmissions (yet) but basically there are multiple worn parts that are all contributing to second gear slipping out of gear.
Not sure how exactly the drum plays a role but I'm replacing it anyway cause it is very worn in one spot as you can see here

nd3qdw

The shift fork is extremely worn and ground down a bit.
I would assume that the wear is causing the dog to not engage as far as it should
(hence it slipping out in the higher rpms)

2rgjk7s

With that in the equation, we now have the 2nd gear output. The edges are rounded off pretty good (from the multiple times its slipped I would assume) therefore it isn't going to lock into gear as well since it doesn't have that straight machined edge and is now prone to slip.


34dpu78

The top gear output has some wear on it as well (obviously since its dogs engage into the 2nd gear output

347agkz
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Last edited by dudewhrsmybike; 02-08-2009 at 01:49 PM.
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Old 02-08-2009, 01:58 PM   #32
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I'm still not sure why there is wear on the 3rd&4th gear output. Never remember having any issues with those gears?

24pi5gp
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Old 02-08-2009, 04:47 PM   #33
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Ok, nevermind...now I see what happened. Hopefully you get her back on the road soon!
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Old 02-09-2009, 11:54 AM   #34
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Gary, I dig your efforts....not too many around here can say they actually dig into their bikes like this. Props to you dude. If it's something I'm capable of fixing, I'll skip the shops too!!!
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Old 02-09-2009, 02:10 PM   #35
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How much in new trans parts have you spent? Would it be more cost effective to purchase the entire trans set?
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Old 02-09-2009, 02:22 PM   #36
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Quote:
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dude if you want to FIX this hook-up with these guys




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PROBLEM SOLVED


+1

For what you are going to spend buying new gears from Kawi, you can probably have R&D do the whole tranny....they still may have to replace a gear or two but they can weld/re-cut a lot of that, then have them undercut the whole thing so you won't have anymore tranny problems. They get around $300-350 to do a tranny not counting any gears they have to replace but its well worth it. Replace the forks for sure, you may be able to save the shift drum though with a fine file and clean it up some...

Have you started pricing the parts you want to replace? if not, you better go look at the prices. If you replace everything you say that needs to be replaced, you are probably talking $600-700+.... shop around bro.

Nice work, feels good doing it yourself doesn't it...
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Old 02-10-2009, 12:29 PM   #37
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Quote:
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Gary, I dig your efforts....not too many around here can say they actually dig into their bikes like this. Props to you dude. If it's something I'm capable of fixing, I'll skip the shops too!!!
Thanks but I'll take my bow whenever I get it back together. I figure anyone can take the apart. Putting it back is another story

Alan, I'm going to replace the stock parts. I'm going through Ronayers and may get a discount. I bought this bike back from ins (kinda regret it) for a pretty penny so when its all said and done, I'll come out okay. Your spot on with the price, its gonna be somewhere around the $600-700 range. I plan on buying a factory pro shift kit as well. I'm gonna skip the undercutting for now cause I want to get this done asap (track season is soon upon us) but I'm at the point of getting all my part #'s together and need to get #'s for fiber gaskets and little things like that. . . . Thanks for the helpful info
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Old 02-16-2009, 12:55 PM   #38
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Parts are ordered (HUGE thanks to Sunny)
I'll let y'all know how the rebuild is going.
I'm a bit intimidated but I'm determined to finish the job, properly.
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Old 02-16-2009, 01:00 PM   #39
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Quote:
Originally Posted by dudewhrsmybike View Post
Parts are ordered (HUGE thanks to Sunny)
I'll let y'all know how the rebuild is going.
I'm a bit intimidated but I'm determined to finish the job, properly.
+1 Sunny works wonders
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Old 03-05-2009, 03:42 PM   #40
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Update: Got all my replacement parts as well as a Factory Pro shift star kit.
Looks like I'm gonna bring everything into the living room this weekend and try to put it back together with the PDF service manual I have on the computer. Oh joy!
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