The dogs are rounded off.

 

yep, 2nd gear is worn. replace it. it's common on r1s.

 

Thanks

Thanks! Do you know if there is an upgrade for this?

 

Thanks! Do you know if there is an upgrade for this?

no there isn't really.... you can try back cutting the gear dogs and that may help, but it will also make it slightly harder shifting into and out of second (but not much)

prevalent in the 98-01 models, the 02-03's get it regularly but it doesn't seem like as much and Yamaha finally pulled it's finger out in 04 and moved from a 3 gear dog design to a 5 gear dog design that fixed the majority of the problem (also happens in early model r6's)

 

Where did you get that bad ass CLOWN!?!?!?!?!?!

 

:cryin im so scared of this happening to me

 

My buddy has the same problem on his 01.... Is it spendy to fix? how much $$$,how much time?? Better yet is it worth it???

 

if you DIY it's not so bad. two or three hundred i believe. CDN$$. but if you go to the dealer you might as well just buy a new engine.. i think my quote for the r6 was $2300 to see what was wrong! there are write-ups around that would help a bunch if you wanted to do it, but it takes awhile, i'm sure.
I left the r6 alone for now, but i think it would be worth it if it was your only ride/your baby. i can't imagine living without cracking on second gear:cryin

 

thanks for the info! J-Seekz

 

Hello All!

My 2000 starting popping out in 2nd around 13,000 miles. I tried to ignore it... but it just kept getting worse. I ended up tearing down the engine and having all the gears undercut by R&D Motorsports in Clearwater, FL. The bike shifts amazing and it not hard to get into any gears... always quick, smooth, and solid! You'll never miss a gear again!

Granted... this is the most expensive option, but it?s also the best IMO! New bikes these days all come with a small degree of undercutting, but it?s nothing compared to the amount that R&D will do. All professional road racing and drag bikes have this process done. It ensures positive gear engagement every time!

In 2007, the undercutting cost me right around $750, plus all the gaskets and whatnot that you need to rebuild the engine. I ended up sending my head out for overhaul, added exhaust, jet kit, clutch conversion, & AIS block-off at the same time... So, I was upward $2200 when it was all said and done! But hey... you got to pay to play!

Call R&D Motorsports and talk to Mark. He is very very knowledgeable on these R1 trannys and will take the time to explain the process to you!

Do a search; there are hundreds of threads on the 2nd gear pop out issue.

But, if you keep pushing like it is and you'll eventually lose the whole gear? or worse!

 

has anyone actually had this happen? like lose the whole gear for neglecting it? what if you never pushed it in second? i'm trying to just get out of the gear early, or roll on slowly to avoid the problem, for now. i doubt i would put another 750USD into the tranny. not on the r6 anyway...

 

great picture, by the way.

 

When 2nd gear "pops-out", the #2 and #6 gear?s engagement dogs ratchet from one set to the next. During this action, the gears slightly separate from each other (hence rounding the edges during the slip and progressively making it worse each time). When they separate, there prying against the shift fork and therefore the shift rods as well.

Repeating this action over and over just continues to wear away and weaken the components. Eventually something has to give, weather it?s the shift fork or one of the engagement dogs. When this happens, the pieces have to go somewhere? and I can almost guarantee you?re not going to like it!

Sure, you could take it easy in that gear? But what?s the fun in that!?! First and second are the best gears! I tried this approach at first? but the problem just continues to get worse and more frequent at lower rpms.

Undercutting the gears isn?t your only option. You can buy new gears and forks and just replace them for much less, but the problem is just going to happen again in time?

Also, you can always search for a used tranny gears or a low mile engine from a wrecked bike and swap them. But, that in itself has its own possible issues.

 

its just thicker washers really

its what guys do to the transmission for built race bikes, its a very common practice on several different bikes, the 'science' behind it is sound, make the gears engauge deeper and they last longer

if you do the thicker washers('shims') and undercut the gears you end up with a nearly bullet proof transmission, but i can tell you the gear shifting if a little rough

 

R&D does great work. never had any issues racing after they did tranny for me. i cant honestly say putting shim in tranny would help alot... problem is... u miss gear just once.. the corner of dogs can get hit and damaged. undercutting puts angle on two dogs so they line up together and not just square. they cant come out. it makes much better. shimming just makes it go into gear little further..but if stock stuff further may not be more than .001 more or so. still doesnt help once u miss gear few times and do damage.

 

R&D does great work. never had any issues racing after they did tranny for me. i cant honestly say putting shim in tranny would help alot... problem is... u miss gear just once.. the corner of dogs can get hit and damaged. undercutting puts angle on two dogs so they line up together and not just square. they cant come out. it makes much better. shimming just makes it go into gear little further..but if stock stuff further may not be more than .001 more or so. still doesnt help once u miss gear few times and do damage.

+1 :thumbup

 

What do you have to replace for 2nd grear slip? 2 and 6 gear + the fork? Or more?

 

It really depends on the extent of the damage. On mine, they were able to weld the dogs on the gears and then re-machine them (with undercutting). Two of my forks had significant scaring them from the gears slipping and pressing up against them, so they were replaced. Also, one of the shift shafts were slightly bent, so it was replaced as well. R&D Motorsports magnafluxed all of the tranny parts. If there were any parts that were suspect, they were replaced.

 

I have a 1999 Yamaha r1. Having the same problems with my 2nd gear as most are. When I hit it hard in second, it slips and jerks and what not, but if I just ease into it slowly or even half throttle, it'll do just fine. From reading other comments, I'm guessing the only real solution is to replace second gear?? I have no problem doing that myself especially if it'll save me money. Just wanting to make to that was the basic solution for the crapy second gear. Thank you.

 

you have to replace 2nd and 6th gear, and all the circlips and the left sift fork forsure, id say replace the shift rod and washers too, youll need to get all the gaskets as well(oil pan, timing, stator, clutch), new orings for lower coolant pipes, new exhaust gaskets

i just finished this rebuild on my 99 last week, hardest part was getting the flywheel off had to take it to 2 different shops, as well as putting the engine back in the frame when your done...had a buddy bring a floor jack and help me, wouldnt have been able to do it otherwise.

the clutch and carbs can stay on but there will be a bracket under the clutch on the lower case that retains the pump chain that has to be removed after you split the cases and before they can be completely seperated. i was able to keep the pump sprocket on and just wiggle the chain off.

cost me about $400 parts and fluids
i had to replace: 2nd 6th, left shift fork, fork guide rod.... gaskets orings circlips ect...

went for a ride yesterday 2nd is strong but found a leak at the oil pan breather hole so have to remove exhaust, oil, and oil pan to fix leak so be sure to give yourself an extra $100 for any f#ck ups

check out supermotojohn on youtube he does full rebuild so just pick out the video parts you need if you want some idea of what to expect...