i would really like if somebody would be able to post up pics of their 05 transmission wheels, that way i could compare to the ones i have sitting here.

 

I swapped mine out with an 05 over a year ago. The only difference is the 2nd/6th dogs. The 05' tranny has 5 dogs instead of 3.

 

Hey bro I rebuilt my trans 8 months ago, its a 05.

This might be helpful but it was never really a how to thread:
http://www.r6-forum.com/forums/showthread.php?t=135347&highlight=

The difference is the number of dogs on the gears, just don't recall atm.
I'll snap some pics after work tonight of the gears in question.

Be sure to check for run out on both shafts. Its only like .0008" which is very slight. If you don't know about run-out ill post a vid later tnight as well.

Just follow the manual, don't rush the assembly, you got this. :jacked

 

There is a good "How To" here http://www.r6messagenet.com/forums/r6-how-guides/82595-how-2nd-gear-pop-out-fix.html?quot;%20target="_blank=

Lots of pics and step by step instructions. This guy didn't swap the whole tranny, just the faulty gears. Good guide none the less. The 05' Tranny is a direct drop in. In fact the 03-05 R6 and the 06-09 R6s tranny will work. I did tons of research before I did mine, and the same thing happened to me which made the decision for me too (sprocket nut).

 

There is a good "How To" here http://www.r6messagenet.com/forums/r6-how-guides/82595-how-2nd-gear-pop-out-fix.html?quot;%20target="_blank=

Lots of pics and step by step instructions. .

ive been looking through the how to guides and i already know how to do it, im just trying to find the differences between the trannys =[ because what this guy did by the looks of it is that he just replaced the faulty first gen gear wheel with a new first gen gear wheel.

 

Hey bro I rebuilt my trans 8 months ago, its a 05.

This might be helpful but it was never really a how to thread:
http://www.r6-forum.com/forums/showthread.php?t=135347&highlight=

The difference is the number of dogs on the gears, just don't recall atm.
I'll snap some pics after work tonight of the gears in question.

Be sure to check for run out on both shafts. Its only like .0008" which is very slight. If you don't know about run-out ill post a vid later tnight as well.

Just follow the manual, don't rush the assembly, you got this. :jacked

thanks for the links and help, and what do you mean by runout???
i think i have runout gauges or something like that here at work (im a crew chief on F-15's in the air force)

 

thanks for the links and help, and what do you mean by runout???
i think i have runout gauges or something like that here at work (im a crew chief on F-15's in the air force)

Bad A§§!

Can you talk your way in to letting me ride shotgun in an F15 for my troubles? :mrgreen:

 

its all good, i need the new gear wheels anyway so im gonna buy the 05 ones, ill compare them as closely as i can to the 02 ones i pulled off and if they seem to match then i will give them a try, if they are different ill probably come back to this thread and say... but thanks for all of the help man.

 

actually, you wouldnt happen to still have your broken gears from the 05?????

 

The 05' tranny had good gears and is in my motor. I still have the 01' tranny in a box, just need the 05 gears to fix it.

 

Measure run-out! its important!
Here is that vid:
http://www.youtube.com/watch?v=Vfhl0uj85zc&feature=youtu.be

and the relevant page form the manual:

You can just replace the two wheel gears you show in the previous pics. Make sure to order NEW snap rings when you order the gears. ALSO inspect the bearing surfaces of the wheel gears, look for galling, scoring or discoloration.

The only difference between the 1st and 2nd gen in the trans is the following:
http://www.r6-forum.com/forums/showpost.php?p=2027915&postcount=45

However, when i ordered a 7 of the 12 wheel gears for mine i noticed that second gear, the one that seems to be the most fragile, had a stress relieve groove down the middle of the gears. That being said, I would order all NEW gears for the ones that are not looking ok.

 

P.S. if you find that your drive shaft is has too much run-out, you'll need to order a new drive shaft & bearing, and press it on the new shaft.

 

i dont really understand the change you added to the shift forks in the manual, will it still engage the 05 gear on the 02 shaft properly?

 

The manual was in Error when it came to the shift forks. This was confirmed by the local shop as well. The transmission will only shift correctly if they are put in properly. Only one way works.

You can check yourself upon dis-assembly, make sure to remove the shift shaft cover and associated components, so the shift drum can slide out.

Manual:
http://www.r6messagenet.com/forums/pdf/03-04R6_service_manual.pdf

 

Bad A§§!

Can you talk your way in to letting me ride shotgun in an F15 for my troubles? :mrgreen:

I wish. I work on the damn things for more than 70 hours a week I haven't gotten to yet lol but I already replaced the upper shaft/shift drum/ shift forks and put it all back in exactly as it was.

 

you still need pics of the shafts gears ect...?

 

you still need pics of the shafts gears ect...?

Nope, I already ordered the 2nd and 6th gear wheels for an 05 tranny to try and compare/put them on my 02 shafts and hope they work

 

damn dude hate to see your luck. I have an 04 r6 that I replaced the trans with an 05 I am trying to find my thread where I had pics of the install. Can't seem to find it. well anyway this is a pic of the complete trans from an 05 r6

 

if that transmission isnt in a bike right now or it you can find disassembled pics of the upper shaft can you tell me the tooth count on the gear wheels that are engaged by the 2nd and 6th gear wheels on the output shaft?? please :bow actually, they shouldnt have any differences because the sprockets would have changed by then instead of 06 so the internals will be the same otherwise it would all be unbalanced.... lack of thought on my part sorry =/

 

The trans is in my bike but I have the original trans which is 04 it is the same I can take pics of that

 

that would be great it they were readily available, if not its ok i wont have my new gear wheels until wednesday so ive got time.

 

the upper shaft is 13 spline and the lower is 15 spline,

 

mis read gotta go re count haha

 

lol i was gonna say thats a few less than expected

 

ok i am confused about what gear teeth need to be counted you can just call me dude 214 548 1472
Jon

 

Hey I'm having the same trans issues I was thinking about doing the swap myself I have some mechanical experience not much tho is there a step by step guide I can use or just something to reference also I'm a bit concerned for a while now every now and then when I go to turn my bike on it makes a loud banging noise and stops completely the power just cuts when I try again. I have to wait a few minutes before I can try again any one know what that can be