FZRSupport: the FZROnline Archive

hey guys, just wanted to see if anyone else has some experience with the transmission. i looked through the whole sticky on the subject but i've run into some issues already. ok, so the "tabs" that hold the shift fork shafts in, i've got one of them off, but i'm not sure how to get the other one off. in the picture its the tab on the left hand side. there's a bolt near the bottom of the tab that comes out, but after that its still stuck in there and i'm not sure how to get it off. any thoughts?


i worked all day yesterday by myself getting the bike prepped for engine removal, once my bro-in-law came home we got the engine out, threw the rolling chassis down the side of the house for more room to work, and started ripping the trans apart. so far, i've got some pieces that seem to be a chipped gear tooth, so i'll be replacing a gear. also the flywheel/clutch basket thing has a big crack in the basket (part that the clutch discs go into) so i'll need one of those, preferably not new as they run $220. along with whatever other problems are in there (ie. shift forks and whatever else is wrong)

that write up has been great help so far, i just wish it explained a little more in depth some of the "easy things". thanks for the help in advance guys!

I have to look into my second gear issue, but it's not so major that I need to do it now. Keep us posted on how things go.

Good luck!

ok, did some digging on the interwebs and looked at the parts fiche for the shift fork shafts, and it looks like the piece i can't get out IS a bolt. i had tried to undo it yesterday using quite a bit of strength and it didnt budge. so i guess i'll give it another shot after i get off work today.

i'll try to do some documentation with pics if i end up doing some more digging. i know the write up just goes over replacing shift forks and stuff, so if i have to replace some gears i'll try to document how things come apart.

anyone got ideas on how to get the timing chain off without buying the $65 chain cutter? this f'ing transmission is going to be the end of me. gotta take about 3/4 of the engine apart just to get the transmission out. i've found about 4 gears that have teeth chipped off, so definitely replacing quite a bit

demon_knight69 wrote:anyone got ideas on how to get the timing chain off without buying the $65 chain cutter? this f'ing transmission is going to be the end of me. gotta take about 3/4 of the engine apart just to get the transmission out. i've found about 4 gears that have teeth chipped off, so definitely replacing quite a bit

well, i suppose if you're going to wreck a tranny, you better go big or go home.

demon_knight69 wrote:anyone got ideas on how to get the timing chain off without buying the $65 chain cutter? this f'ing transmission is going to be the end of me. gotta take about 3/4 of the engine apart just to get the transmission out. i've found about 4 gears that have teeth chipped off, so definitely replacing quite a bit

Well, this tool seems to be ok for a pesky computer.. try it out:

LOL2 so no one has replaced their timing chain using anything home made, or a cheap tool from the auto store? it really sucks, to get the trans out you have to split the crankcase, but in order to do that you have to take the head off just for 2 bolts. thats it, just two. i would feel a bit better if there was half a dozen bolts under there, but its only 2

so yeah, fun times