Help!

[ssr_drifter]

I go by the name Drifter, I am the Sgt. @ arms with Secret Service Riders (California chapter). My 02 954 just went into the shop, in second gear and only in second gear when you get into the power band it feels like if you were to pull the clutch in, then release it all the sudden. I just about high sided the thing because of this problem. I was in a sweeping right hander at about 75mph when it did this causing loss of traction when it happened. The shop said they have never heard of any such problems with the 954's and are charging me $350 just to look at it (then $350 more to put it back together plus what ever any parts cost). If anyone has any idea what might be the cause of this please contact me, reply to this post, place a post on my club web site secretserviceriders.com or e-mail me at ssr_drifter@yahoo.com Thank you for any help, and if anyone is in the LA area look us up if you ever need a favor.
Drifter.

[66droptop]

Any chance you are using automotive oil? Additives screwing with your clutch?

[Sime]

It's really not difficult to pull the clutch out yourself. You would save a LOT of money that way! Take the bike back from the 'stealer' and get all DIY!!

I can't see how they are charging you for over 4-5 hours of labor (at about $65-80 an hour) to pull the clutch out. That's ridiculous! You can do it in about 20 minutes....if that!

Good luck. Please keep us informed of your progress.

[ssr_drifter]

Nope on the oil. Motorcycle oil only. The clutch is a new EBC kit that i put in as soon as the problem started, now the clutch feels great but it is still not sticking in 2nd gear.

[NIHILator]

Hmm clutch slip in second gear only........And you say its not when you engage the gear but when you hit a certain RPM? Thats odd... Sounds like if you replaced the clutch with an EBC kit that should rule that out. I had a slip problem on my ZX-6 and the first thing i did was replace the clutch with kevlar race items and HD springs. It wasn't the problem either. It was a tranny problem. Second gear takes the most abuse, I would suspect worn teeth or something similar. Sounds like it might be worn and hold until the big torque hits, then it can't handle it.... But wait, you say that it grabs again hard?

[ssr_drifter]

Yeah, the thing just about high sided me the last time I rode it. As soon as you are about a thousand RPM or so into the power band, it feels like if you were to pull the clutch in all the way then just release it. Like I said the bike is in the shop now and they should be getting back to me by Monday or Tuesday next week. I will put a post up and let you guys know what they say. I have hit up a few sites and forums and so far I am the only lucky one with this problem. I was so pissed off when the shop told me what I was looking at cost wise, I almost traded the thing in on a R1. but for me to do that I was looking at a bit more money, and I have been a Honda guy for about the last 10 years. I love the way the Hondas handle and I am happy so far to hear that not many other people are having problems with the bikes. Maybe I will keep being a Honda guy. Thanks for the replies.

[blayne]

i may have a similar problem.
i came around onto a nice straight section (rural roads) in first. wound her out to near redline (about 10k), went for second gear, engaged, power back on and suddenly (like pulling the clutch in) revs out quickly and then returns to normal. it felt like a false neutral but it was in gear enough to gain revs and be past the point where it could be a false neutral.

this has happened twice. just had the service and told the mechanic.

his response was "ooh, that's not good"
but when they pulled the box and checked it out, there were no signs of trouble.

Drifter, do by chance shift without the clutch? i upshift without and sometimes down shift (i know its bad)

[ssr_drifter]

Nope on the shifting without the clutch, My bike is STILL in the shop. They said they pulled everything apart and nothing is wrong so now they have to pull the motor and crack the case. The only porblem with that is they had to order a tool to get the motor out and that took an extra week and a half to get. I have been told they should know what the problem is by the end of this week but I was also told that they would have my bike back to me no later than two weeks after droping it off.... and we all know how that works. On a side note being that I am a "Biker" and I have been going nuts over not being able to ride, I jacked my friends R-1 and let me say they suck! sorry all you yamie guys but the bike is not for me! I am glad I could not trade my bike in on that R-1 when it broke

[NIHILator]

Sorry to hear your bikes still broke. I haven't ever driven a Yamaha except the first gen FZR1000 i think it was. The genesis one with the five valves. At the time it was cool. But with the new bikes i don't like the Kaw's and the Yam's at all. And all the bikes i ever had but this 1000RR and one crappy suzuki were all kawasaki's. I got two ninja's in the garage right now. But the new ones are butt ugly.

[Kubiekdriehoekje]

Originally Posted by blayne

i may have a similar problem.
i came around onto a nice straight section (rural roads) in first. wound her out to near redline (about 10k), went for second gear, engaged, power back on and suddenly (like pulling the clutch in) revs out quickly and then returns to normal. it felt like a false neutral but it was in gear enough to gain revs and be past the point where it could be a false neutral.

this has happened twice. just had the service and told the mechanic.

his response was "ooh, that's not good"
but when they pulled the box and checked it out, there were no signs of trouble.

Drifter, do by chance shift without the clutch? i upshift without and sometimes down shift (i know its bad)

This sounds like worn friction plates and springs or full synthetic oil instead of half synthetic causing the cluth to "fade" under maximum load. Have had that with 2 of my '97 CBR600s (and with my Kwak as well, but I'm trying to surpress the memory of working on that bike...). 1 new gasket, new Factory springs and new friction plates and voila, problems were solved.

[ssr_drifter]

I called the shop today and found out that it is the dogs, oh yea and after over 150k miles on various bikes in the past 13 years of riding (30k miles on this bike), I DO NOT KNOW HOW TO SHIFT! at least thats what the shop said. They said that I rounded off the dogs by "banging through the gears". I kinda expected to hear that it was going to be my fault, I don't agree but at least I am one step closer to riding MY bike again. They said I am looking at $1500.00 + to fix and 3 more weeks in the shop. I should know the price by Thursday. I did ask the guys at a different shop and they told me that the price is about right, however they said that they have had that type of problem covered under the warrantee. I still have hope that the cost of repairs will be covered, but if not I am ready to money up . I will post what ever I hear as soon as I hear it.
-Ride Safe!

[NIHILator]

Yeh figured it was the tranny. Sorry to hear so expensive.....

[Kubiekdriehoekje]

Originally Posted by ssr_drifter

I called the shop today and found out that it is the dogs, oh yea and after over 150k miles on various bikes in the past 13 years of riding (30k miles on this bike), I DO NOT KNOW HOW TO SHIFT! at least thats what the shop said. They said that I rounded off the dogs by "banging through the gears". I kinda expected to hear that it was going to be my fault, I don't agree but at least I am one step closer to riding MY bike again. They said I am looking at $1500.00 + to fix and 3 more weeks in the shop. I should know the price by Thursday. I did ask the guys at a different shop and they told me that the price is about right, however they said that they have had that type of problem covered under the warrantee. I still have hope that the cost of repairs will be covered, but if not I am ready to money up . I will post what ever I hear as soon as I hear it.
-Ride Safe!

Is the shop you'rew at now a Honda dealer or recognized (by Honda) repair shop? I know that someone over here had the revision costs payed by Honda for a 2001 929 engine with 30000km. They just said that it shouldn't be breaking down in that way, so it must be a manufacturing flaw...

[Sime]

I have an alternate idea for you. Tell the repair shop to go stuff themselves!!!! 3 more weeks....bah!!

If you've done 30,000 miles on your 954, why don't you just buy a complete lower mileage motor/tranny off Ebay. You can get them for under $1K. Easy to remove/replace. What if the problem with your dogs has sent metal filings into your motor as well, leading to its premature death? You could put the replacement motor into the bike inside of a day - or less.

You could still sell your motor on Ebay in parts and probably make back what the replacement motor cost you - maybe even much more! You could sell things like the head, cams, rocker cover, stator and stator cover, tranny cover clutch basket etc

Just a thought.

Here are some links that might interest you:
HERE
AND HERE

The first one seems like a great deal. Currently at $200 and under 2 days to go. $1500 just to repair the tranny on a bike that you can buy with much lower miles for under $6K is silly. I saw an excellent condition '02 954 sell today on Ebay with 5500 miles for $5800 for the entire bike!

Good luck!

[ssr_drifter]

Hey thanks for the info, I am still waiting to see if the repairs are covered but I will look into taking your advise.

[ssr_drifter]

Well it’s the shift dogs. Bad news is i have to pay for it. Due to the fact that I changed the clutch plates Honda said they have no way to show the damage was not caused by a worn clutch. I offered to show them the clutch plates that i removed but they were not willing to pay... The good news is that due to the design of the motor/transmission the total cost of replacement of all of the dogs labor and whatever else they are charging me is going to be $1250.00 not the original $1500.00 + they said. I guess this is one of this things that suck in life... but much like divorce, we pay the money because it's worth it! The bike should be home by next weekend as long as all the parts come in. Thanks for all the info guys!