$4k sound crazy. Don't you have a three piece crankcase and we're talking about removing the lower crankcase to replace failed transmission parts? Can you do things like removing & reinstalling the engine? Check the magnet on the drain plug or the strainer in the oil pickup.
6th gear has left the building
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Started the disassembly today, got everything disconnected and the engine is ready to be dropped. Dropped the oil pan to have a look inside, it's pretty gnarly and there was more in the drain pan when I drained the oil as well. Though I have seen much worse in other forum posts where people replaced broken gears so I'm hoping I can make this work.
Now just waiting on the tool for the engine mount thrust adjuster nuts.
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@SparkyMJ The bike only has 24k miles! The clutch is working fine, I can shift through the gears with the bike on or off no problem. The "bad shifts" I was referring to only happened when using the quick shifter, not exactly sure why. When I purchased the bike the shifter where it clamps onto the shift shaft was loose so perhaps the previous owner had caused some damage. Also the actual shift lever where it mounts to the footpeg, I think the bushing is worn out because there is a fair amount of play in it. I'm sure that didn't help either.
Now just waiting on the tool for the engine mount thrust adjuster nuts.
@SparkyMJ The bike only has 24k miles! The clutch is working fine, I can shift through the gears with the bike on or off no problem. The "bad shifts" I was referring to only happened when using the quick shifter, not exactly sure why. When I purchased the bike the shifter where it clamps onto the shift shaft was loose so perhaps the previous owner had caused some damage. Also the actual shift lever where it mounts to the footpeg, I think the bushing is worn out because there is a fair amount of play in it. I'm sure that didn't help either.
It looks like you have it in hand, but my 2c. I had 5th go on the back straight at Donington. K5 750 with 18k miles and a quickshifter (PC3 quickshifter in that case). I've spoken to a guy at the track with a K5 600 who also broke a gear and blames it on the quickshifter. Anyway, make of that what you will.
I did the whole job myself. I dropped the motor, flipped it over, took off the sump and sub-block and the whole gearbox is right there. To be clear, it's still a lot of work pulling stuff apart, but totally doable. In my case, the shift fork was worn pretty badly and the dogs on 5th were badly rounded. I think the fork wore and then was under-engaging the gears.
So I bought a second-hand gearbox from a 2017 GSX-S750 and replaced all the gears and one of the shafts. And turned the buggered fork into a keyring.
Take lots of photos, collect bolts and bits that go together in ziplocks and crack on.
Edit: I've DM'd you my album of photos from my rebuild.
I did the whole job myself. I dropped the motor, flipped it over, took off the sump and sub-block and the whole gearbox is right there. To be clear, it's still a lot of work pulling stuff apart, but totally doable. In my case, the shift fork was worn pretty badly and the dogs on 5th were badly rounded. I think the fork wore and then was under-engaging the gears.
So I bought a second-hand gearbox from a 2017 GSX-S750 and replaced all the gears and one of the shafts. And turned the buggered fork into a keyring.
Take lots of photos, collect bolts and bits that go together in ziplocks and crack on.
Edit: I've DM'd you my album of photos from my rebuild.
It looks like you have it in hand, but my 2c. I had 5th go on the back straight at Donington. K5 750 with 18k miles and a quickshifter (PC3 quickshifter in that case). I've spoken to a guy at the track with a K5 600 who also broke a gear and blames it on the quickshifter. Anyway, make of that what you will.
I did the whole job myself. I dropped the motor, flipped it over, took off the sump and sub-block and the whole gearbox is right there. To be clear, it's still a lot of work pulling stuff apart, but totally doable. In my case, the shift fork was worn pretty badly and the dogs on 5th were badly rounded. I think the fork wore and then was under-engaging the gears.
So I bought a second-hand gearbox from a 2017 GSX-S750 and replaced all the gears and one of the shafts. And turned the buggered fork into a keyring.
Take lots of photos, collect bolts and bits that go together in ziplocks and crack on.
Edit: I've DM'd you my album of photos from my rebuild.
Thanks so much man, really appreciate it. That's interesting to hear about the quickshifter issues you guys had. I'm going to have to really figure that one out before I use the quickshifter again. I am going to throw in a Factorypro shift star and spring while I'm in there, hopefully that'll help with the sloppy shifting.
I'm surprised to hear a GSX-S gearbox works in this bike. I would've thought those bikes had different gear ratios? I see a few for sale on ebay but it's hard to tell from the pictures what kind of wear is on the gears and dogs. Anyways I'll only consider what parts I need once I get in there, hopefully it's not too catastrophic lol.
While you're there, you might want to consider a different drain plug. I discussed it here six years ago but the pics were on TinyPic and no longer available. I cross-drilled the head for safety wire and made a small tab on an oil pan bolt for the wire's other end. The AliExpress link still works. I can resurrect the pics if you're interested. As I recall, its magnet is better positioned and more powerful than Suzuki's.
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