Kawasaki Sportsbike Riders Club - Australia - Online Forum

Hey all i recently bought a '94 zzr600 off ebay and i realised that apart from needing a RWC and rego i have some gearbox problems

did a search n apparently zzrs are known for the gearbox gettin stuffed.
well i think mine does that as well

it skips occasionaly and i sometimes get neutral between 2nd and 3rd and it FUCKED UP today and i stalled on north road grrr

any advice from fellow kwaka riders? sell it, add oil get it regod

plz help i loove it, its my first big bike n i dunno wat to do

couple of options I guess being Vic bike wreckers or perhaps someone here might be able to rebuild a gearbox, failing that, look for anther ZZR600 and between the two get one working bike.

step 1, buy a manual for the bike, haynes = good!
step 2, change oil, you might be lucky and the oil levels low/the oils farked.
step 3 if you've still got problems and have got the time & nous. Drop the motor, split the sump and make sure the dogs & forks arent pitted & bent. If they are, you'll be up for some coin for replacements.

paying a shop to do it would be an absolute SHITLOAD of cash as theres a lot of labour involved. There'd be not much change from $1200 at a guess.

could be a cheaper option to just buy a whole new engine from a wrecker, even exchange the one you've got with them nd it may be cheaper again.

the reason i suggest this is because i had problems on my 94, it was repaired under warranty - the labour bill was horrendous and the whole job was costed at >$5000

and new mota should be less than half of that

more than likely your problem is the gear selector dogs, they get bent and wont engage the gear properly

HTH

thanx alot for the advice
i noticed if i kinda push the gear selector before i shift it is much smoother. i barely scraped the money together to get the bike so a new engine/gearbox is not an option just yet
i guess the oil change might be the way to go
could it be the clutch tho rather than the gearbox? im just curious and im grasping at smoke here but maybe koz the clutch is knackered the gears arnt engaging bla bla bla

i dont wanna buy a new engine/gearbox


the bike has done an apparent 30,000Ks as its been standing for a while. but ye i dunno..

Mine's a '98 and it's done close to 65,000km on its original clutch. I know that I'm not that hard on the bike (and I have done the last 47,000km) but only 30,000km doesn't seem quite right.

I had issues similar to what you're describing when my cluctch was out of adjustment. I got false neutrals and because the clutch lever was also not correct, I couldn't start the bike (the neutral start switch wasn't being actuated properly). The side-stand switch was also a bit dicky as well...

It may be worth checking it into a Kwakka dealer and letting them have their evil way with it. You never know, it may be a combination of mis-adjustments.

Good luck with it...

Not sure if anyone has mentioned it...but Chain. Both the tension and the condition of the chain and sprockets can actually affect gear changes too. If they are stuff, it can add to an issue.

Strika wrote:Not sure if anyone has mentioned it...but Chain. Both the tension and the condition of the chain and sprockets can actually affect gear changes too. If they are stuff, it can add to an issue.

Good point...

I would also say have a look at the clutch relaese lever and the pin it pulls on that sticks out of the middle clutch, i just replaced mine well almost and in my case there is plenty of wear in the original parts and certainly enough to cause shifting problems.

or there is just a very well documented issue with the ZZR (E7-13) Series, second gear probably needs to be replaced. They started doing it in the states for free after to many people had issues.

Mine's a 96 model, done 105000 or so k's, about 60000 under my arse, as best i'm aware still original cluth and gearbox...

Now have a rattle in teh clutch basket but advice seems to be it can still do another 100,000k's, did replace clutch springs trying to eliminate the rattle but didn't happen so I live with it now.

Check and adjust everything as mentioned above, then if you decide to do the gearbox yourself, have a look at this to see what you are in for.

http://www.ksrc-au.com/index.php?itemid=91

I can't remember exactly but I think it cost me around $700 to do it myself