My gearbox :(

[superstacker]

Guys, my ZZR gearbox has developed a fault, basically jumping out of gear in second and third as well i think, now im sure i can take the engine out to get to the gearbox, but i have no idea on gearboxes, any chance a fellow essexbiker could take a look at it sometime? I would be able to transport it wherever :)

any help appreciated!

lee

[DoodleBug]

What have you done to my former baby?

I wish I knew about gearboxes mate, I'd love to help but I am clueless.

[Lateshift]

Guys, my ZZR gearbox has developed a fault, basically jumping out of gear in second and third as well i think, now im sure i can take the engine out to get to the gearbox, but i have no idea on gearboxes, any chance a fellow essexbiker could take a look at it sometime? I would be able to transport it wherever :)

any help appreciated!

lee

its a ZZR if its jumping out of gear whilst in 2nd or 3rd then its very likely you have bent gear selector forks :(

if you are a fairly competent mechanic its an easy enough job to do but getting hold of the parts might not be as easy for the ZZR400 (although i think the ZZR600 ones are the same?)

if you stick it in second and try to nail it hard, and it jumps out of gear then i will put money on it being that ;)

[DoodleBug]

Hmmm, as far as I know, the only internal differences between the 6 and 4 was the barrel and piston assembly. 'box should have the same parts.

[gixer400]

would a zxr gearbox fit do you think??if so ive got a good one, and good selector forks.

[DoodleBug]

They are the same block, and if you look at the stickers on the bike, being an import, its labelled as a zx400r ISTR.

[Lateshift]

I will have a look at the ZXR400L manual tomorrow at some point, and see if there is any similarity :)

[gixer400]

cool. if thy are the same, i have 2 spare engines which im sure i could donate a gearbox and forks for a burger and coke from the white hart one day :)

[Lateshift]

a very quick scout around without looking too hard suggests that this is a common problem for all the ZZR's

however it could be a few possible causes,

first, the gear change linkage may need adjusting slightly, due to 2nd gear getting a fair bit of use (especially on the 400's) it may well be that the gears are slightly worn and that the linkage isnt allowing it to engage/disengage smoothly.

secondly, the gears as mentioned maybe worn in which case we are talking about a full strip and repair, a recon or newer gearbox would be the way to go though as it would cheaper than the labour (unless you get a good garage to do it).

lastly, as i suggested the gear selector forks are bent, this is a fairly common problem and one that does need a strip to get to, but with it being common is a pretty standard job.

[EverSoSlightlyFasterThanU]

i had ted the same thing with my vfr and it was the forks

[superstacker]

Cheers for the help guys, when im next down ill decide fully on the plan, thanks for the offer of the gearbox mate :)

Im guessing a bent selector fork wouldnt be obvious to a mere storeman like myself?

[Lateshift]

well it wont be straight if thats what you mean? :D :D

[Max Lean]

I ha d the same problem on my 1999 ZX6R G2, its a common kwaker problem...

I turned out to be worn dog gears in the end :(

I managed to source a complete box from ebay for £6 lol

If you are a half decent mech you should be able to do it your self.

the only probs are getting the clutch basket off if you aint got the special tool....

[gixer400]

the only probs are getting the clutch basket off if you aint got the special tool....


too true, mines in about three bits now because i thought brute force would work. glad i had 3 engines too choose from :)

[Max Lean]

too true, mines in about three bits now because i thought brute force would work. glad i had 3 engines too choose from :)


Another speaks from experience lol

And if you swap or take out the selector drum, make sure its in the right way round :reading

I ended up with 4/5/6 th and nothing else because it was 180 degrees out lol..

which means sump off clutch out and and alot of fiddling before its the right way round :eyewobble

[superstacker]

So just to confirm, if i were to look through ebay for a ZXR400 engine, then that could be dropped into my bike complete?

[Max Lean]

Try this
http://cgi.ebay.co.uk/BREAKING-KAWASAKI-ZZR-400-MOTORCYCLE_W0QQitemZ8059978562QQcategoryZ10464QQrd Z1QQcmdZViewItem

[superstacker]

Cheers have emailed him, not too far away from stafford either, just may need some mecanically minded mates to help me fit it ;)

[notaclue]

Cheers have emailed him, not too far away from stafford either, just may need some mecanically minded mates to help me fit it ;)

Did you get it sorted? 2nd gear was a problem for YZF600 too. Just waiting for mine to go :(

[RaceMeNSee]

i find faulse neutrals everywhere on my zx6r G1!!! Its as annoying as feck! Hope you got your problem sorted!