Kawasaki Sportsbike Riders Club - Australia - Online Forum

...another update. Pulled the selector drum and forks out last night and the one that does the stuffed third gear has some nice big grooves in it. That, combined with the end of a circlip that we found in the oil pan, suggests that the third gear damage was a result of a broken circlip causing a loose gear which stuffed the selector fork which meant third didn't engage properly which lead to the damaged dogs.

It's good news in a bad news kind of way. At least I should be able to fix it. Now I'm just waiting for the 2nd hand box to turn up and I'm off at lunchtime to order the 5 million gaskets, seals and nuts that I need to get to put it all back together again

Damon ZX9R wrote:Mick c ,your cd manual will be in the post tommorrow hopefully.

Got it last night, thanks again

Most of the gaskets, seals, o-rings and doohickies have arrived, as well as the gearbox, so it looks like I'll be getting my hands dirty this weekend...OK, maybe tonight

great work on finding the problem.!

Good luck with it all, I'm glad its you and not me, I hate gearboxes....

You should get one of these when you rebuild the motor to reduce wear on the motor http://www.motorcycle-parts.com.au/Filter%20Plus.htm

Faaaark, the gearbox they sent was as bad as mine. Had a word and they are going to send another one. The guy I spoke to is going to check it himself this time, if it's no good they will refund me and I'll have to buy new bits...bugger!

Sounds like mine when we pulled it down,they really are shit. Good luck, i forsee many test rides for you shortly.


Stu

split the crankcase on my zx9 the other day to find my second gear problem and it sounds suspiciously silimar, groove worn into the shifter drum and a shagged selector fork(s)
dogs look ok though
Still just getting the forks and drum is a mission from kawasaki

Sounds like everyone has been enjoying themselves taking gearboxes apart while I've been on holiday, I'm starting to get worried myself!
How many K's have you got on your 9's and what was the fault that caused the dismantling..........
The worst part about my box is the false neutral between 3rd and 4th, that can be a bitch if your not firm with your gear change.
Copped that neutral once on an open bend, I had my new boots on and they just applied a little upward pressure to the gear lever mid bend and "Hey Presto" instant power loss. WOO HOO!
All was good though.
Keep the link informed on how go, I would like to know, as I will know who to come to when mines buggered
Be Good

bout 60 000km on my 97 now.
Fault was a groove worn into the shifter drum by the selector fork base.
Gears and dogs looked almost brand new

Yeah, was the 97 model the same gearbox as the 98 as I remember the ZX9 went through a lot of changes 97-98.
Mines only on 33000 so I should have a bit to go, I've heard people with stories of high miles and they aint even opened the motor.
I reckon a lot of it can be what sort of treatment its been through from previous owners, crash gear changes, lots of stick etc etc.
Hopefully with TLC and plenty of good oil, I may get a few more years out of her yet, or until the ZX10 prices come down anyway.
Thanks for the reply.
Later guys

98 was completely different to 97

yeah, I guessed it would be, they reworked everything, I just wondered if they had changed the box aswell.
Thanx

Damon ZX9R wrote:yeah, I guessed it would be, they reworked everything, I just wondered if they had changed the box aswell.
Thanx

Yep and not for the better

ya reckon?
It shed like 40kg i thought that was pretty good.
Id kill for a newer 9