2006 Ratchet noise from Gear box when accelerating

[c10]

Friends 1300 with 48,000 miles . I went , and swapped bikes with him at work to see what its doing .

4th gear roll on , and man it sounds bad . feel it in the left peg . Wouldn't do it in 3rd or 5th , but later I rolled on

1st gear pretty good . It did it in 1st as well . I was thinking bent shift fork/drum not being held in the correct position

I wonder if the drive shaft splines are damaged ?

Thanks c10

 

[Fred W]

No... not drive shaft splines. Much worse. It's the transmission's gear dogs and shift forks. Usually happens on 2nd gear (probably 'cause that's where we whack the throttle the hardest), but can happen on any.

Requires splittin' the cases to fix.

 

[ionbeam]

1) Agree with Fred, transmission. Usually 2nd and 4th but could be another gear.

2) In the FJR it is almost always worn gear dogs and bent/damaged shift forks.

3) Agree with Fred, the only fix is to split the case. The other option is a replacement used engine with the risk it may have the same issue and you won't know until it's in the frame. At that point if you have a warranty, whoopie, you still have to pull the engine again, return it and gamble on yet another engine unless you know the source.

 

[c10]

Thanks Guys . I pulled the pumpkin . Splines are DRY but not striped or missing teeth .

Little history . I met Don a month ago . His bike was in poor condition with dual blown fork seals , car tire leaking , Leaking thermostat housing , and many other items .

I took on his bike . Replace every coolant hose , Cap , T stat , valve adjustment , valve cover gasket , rebuilt forks with new seals , bushings , wipers , Hagon springs , replaced leaking shift shaft seal , Spooned on new PR4 tires / balance , balance throttle bodies , changed oil/filter , mod airbox / clean K&N filter , repair sticking rear brake , clean windshield tracts/ regrease , disable auto down function , clean bike up from all the leaking oil .

I took a new sargent seat in trade , and $500 cash for my work .

Man I feel bad for Don after all this work to get this just a few days after he got it back from me .

 

[stealth1]

Good luck with the repairs c10. I know it's in good hands.

Last time I saw you was at Eureka Springs on one of the ZRX weekends 4 or 5 years ago. I had sold my ZRX and bought a FJR. I think you were riding a Suzuki dual sport that weekend.

I've moved west to Utah since then but those ZRX weekends are hard to beat.

John

 

[c10]

John are you still visiting the ZRXOA ? Don , and I talked it over tonight . He has a friend at a yamaha shop . May see if we can pull motor for them to do the trans work . Then we will re install the motor . I just dont have the time to do the work myself for Don . I'm still a 4 to 6 month turn around on

ZRX engines for the remaining ZRX drag racers that are local to myself .

 

[stealth1]

Have not been active on the forum for a couple of years. My name was notinsane on that board. I did log on to it the other day and saw my old ZRX listed for sale for $2000. Looked like the guy I sold it to had an incident that cracked the fairing and dented the tank on the right side.

Special Ed came out here summer before last and I rode some good Utah and Colorado roads with him.

 

[wfooshee]

4th gear dogs from my recent debacle. That's not supposed to be a bevel!!!

Shift fork for 4th gear:

If you want to see what's involved in splitting the cases, start about here in my thread on the subject