my 2nd gear is poping out. i just bought the bike from a buddy that i ride with he had went down on the bike and broke the clutch lever and the shift peg. i bought the bike from him threw the whole peg asmbley with shift linkage and a clutch lever and housing on it i took it out and its poping out of 2nd..

could it be that the shift linkage or clutch it not adjusted right? or is it some how a shift fork? it never poped out on him when we would ride......

also i noticed after taking it out that the oil is too full could that have anything to do with it?

2005 636

 

if it never done it before. AND YOUR SURE OF THIS then your "fix" is the problem


keep it over full on oil. that's common

 

05/06 636 trannies are notorious for breaking. I had mine brand new no more than 8 months and the shift dog, shift fork, and 2nd gear went out. I had the same symptoms as you are having.

Cost me $1400 to repair.

 

ya same **** happened to my bike. i switched both sets of gears and the shift forks from a blown motor and **** was a ok. but this is not for somebody that doesnt know what theyre doin

 

tranny took a ****


if its anything like my honda (and most bikes) then you gotta pull the ENTIRE motor apart to fix it (head, pistons, then pull the bottom end apart)

Just ride it as is and skip 2nd, ride it tell it blows, then buy a new motor. Thats what I'm doing

been on a f4i with no 2nd gear since 16k miles, at 33k now

 

could it be that when i threw the new parts on i didnt adjust em right?

 

its something that happens over time, it had to have been doing it for your buddy i would guess or you just got really unlucky and it just happened when you first rode it.

 

its common on 636's

kawiforums.com ... do a search on that site. tons of posts on this problem.

i have a 636 and i just went GP shift and problem was solved.

sad thing to say is.. it just........ happens :\

 

IMO, I think it happens from people banging gears, and sometimes missing gears.


The guy I bought my f4i off of always shifted 1st to 2nd gear wheelies with no clutch

And when my 2nd actually went out, I let another friend borrow my bike for a week, and all he'd do when he was out on it is was bang gears trying to go fast as possible, then he brings it back to me with no 2nd gear

 

sounds like a common problem..my buddy got an 03 last yr and it slips outta second also!

 

If you firmly change gears it doesn't happen at least with the 636. If you shift softly then it will happen because you might think you're in 2nd but its kind of on the edge of 2nd and it will eventually wear out the shift fork I think its called. But clutchless shifting from 1-2 isn't a good idea to begin with because you're passing through neutral you should clutch 1-2 and then 2-3-4-5-6 can be clutchless all day. My 636 has hard non stunt miles on it and Im somewhere around 12k mi I think right now and the tranny is perfect (knock on wood), always shifted firm and rarely cluthchless between 1-2. my

 

damn i figured it was just messed up but thought maybe there could be another reason damn lol well i will take the bitch apart and let yall know thanks alot

 

Mine will pop out from time to time also. It's usually happens after a weak shift. feels like it needs to be slammed into 2nd or it will pop out.

 

i seen an another forum that to check the forks you dont have to take the engine out just the clutch and the pan anyone got any info on this?