3rd Gear

[MickLC]

OK here's what's happening. Every gear but 3rd is fine, but when I'm in 3rd and the bike is fully warm (i.e. I have been riding it for about 10 minutes), I open the throttle and the whole bike lurches. It's like it's slipping out of gear for a fraction of a second then going back in again. The engines spins faster when it does it, then the whole drive train gets a jolt when it comes back in.

I got to play with it a bit on the ride to Kangaroo Valley yesterday and found that if I accelerate it will do it once and then be fine as the revs rise, but if I back off or feather the throttle it will do it again. If I change up from 2nd and hold the gear selector up it will still do it, but if I change down from 4th and hold it down it won't do it.

It doesn't make any really bad crunching noises, but then again with the speed I'm going, the noise from the pipe, and the sound of the chain wipping around you can't hear much else.

Now I know most of you are going to say "Gearbox is stuffed mate, it's gunna be expensive", and I'll agree with you...but if anyone can give me a better idea of exactly what it is that's probably stuffed and how much is involved in fixing it I would appreciate it cause I don't want the workshop leading me up the garden path.

Thanks guys.

[MickLC]

I've been doing a bit of looking around on the ZX9R forum and it appears that this is a problem with the C1 model ZX9R as the dogs get worn and 3rd doesn't engage properly. The selector fork can be bent as well.

There's a fair bit of discussion about it here http://www.kgrant.co.uk/Forum/phpBB2/vi ... .php?t=324

[Nanna10r]

Glad you've found some info Mick, the "Tiggr's" Box has always found a false neutral from 3rd to 4th if i am poking alomg n use too light a touch on the stick. May have to keep this in mind if it gets any worse.
Cheers Brett

[MickLC]

From what I can tell it wasn't as much of a problem on later models, but yeah you'd want to be careful with it.

[Wannabe]

Bugger. Real bastard that

[mrmina]

"Tiggr's" Box Cheers Brett

i thought u said ur bike was a male.

[MickLC]

Geez Mina, I was hoping for some help and advice, not smutty innuendo. I know we all do it at some time but leave it to the off-topic posts please.



Has anyone had to have this kind of work done on their bikes? How much did it cost?

[Wannabe]

Mick prices will vary depending on whether you want to take your engine out yourself take the bike to the mechanic as is.
A guy I know recently had 2 gears & shift forks replaced on his R6. Some of the quotes he had been given were highway robbery so he shopped around & found a good mechanic with a realistic price.
He took the motor out himself & I believe the cost was approx $850.

Basically it could cost you anything from $500 - 2000. I suggest you ring around and get some exact prices 'cause I'm only estimating & I don't know how much the ZX9 parts will cost. Best of luck mate

Tony

[ZX-10R_04]

"Tiggr's" Box Cheers Brett

i thought u said ur bike was a male.

You would think it would be a Tranny then

[MadKaw]

Sounds like it could be the clutch... I'd check that before spending big on the gearbox.
Mine use to spin in 4th gear until I put some Barnett springs in it.

The gearbox in my 9 has had the gears undercut but it still kept getting false neutrals. I fixed this up by putting a factory pro shift kit in it.. best thing I ever did....

[Wannabe]

Sounds like it could be the clutch... I'd check that before spending big on the gearbox. Mine use to spin in 4th gear until I put some Barnett springs in it.

If it was only spinning up then I'd agree with you MadKaw, but the fact that he says it 'lurches' like it's slipped out of gear and 'the whole drive train gets a jolt when it comes back in' really does sound like gearbox.
If the bike has done a few k's then it might not hurt to fit a new clutch or heavier springs anyway though but I'm afraid it sounds like more than that. I hope I'm wrong though.

[Nanna10r]

Sounds like it could be the clutch... I'd check that before spending big on the gearbox.
Mine use to spin in 4th gear until I put some Barnett springs in it.

The gearbox in my 9 has had the gears undercut but it still kept getting false neutrals. I fixed this up by putting a factory pro shift kit in it.. best thing I ever did....

how much dave ?. Got about 6 false neutrals today & its only done 15 thou ks went fully synth too, like tha helped .... NOT.
Cheers Brett

[MickLC]

Sounds like it could be the clutch... I'd check that before spending big on the gearbox.
Mine use to spin in 4th gear until I put some Barnett springs in it.

The gearbox in my 9 has had the gears undercut but it still kept getting false neutrals. I fixed this up by putting a factory pro shift kit in it.. best thing I ever did....

As Wannabe pointed out, it feels like it is dropping in and out rather than slipping, although it might be worth popping some beefier springs in anyway when I've got it out.

Speaking of which do you or Phil or anyone else have a workshop manual for the ZX9 that I could get come bits scanned out of or borrow for a short period of time while I scan it? My mechanic mate is keen to have a go at doing it ourselves, and I'm looking after a ZZR1200 for another mate while he's overseas so I'll still have transport.

[MadKaw]

A sticking or warped clutch can give a similar effect as it is slipping then grabing and will learch the driveline as you have it at revs when it grips again... Just some food for thought... may not be, but a cheaper fix if it is..

Sorry Mick I don't have a manual but you can check the parts diagram at http://www.buykawasaki.com

Brett, the kit cost about $160 form Factory Pro in the states. There web site is at http://www.factorypro.com and when your in the zx9 section check the story at the bottom of the page for the 98 / 99 model... I know that guy..

[MickLC]

It will be worth checking out I guess, certainly a lot easier than the gearbox. Where did you get the Barnett springs?