Gearbox.......

swarb · Post by **swarb** » Wed Apr 20, 2005 1:59 pm

Hi, if this post appears 3 times, sorry.....!!

Having trouble wih the gearbox, bike is a '96 L, gearbox is fine in every other way, doesn't jumo, isn't notchy etc, but when going up from 1st to 2nd thru neutral, about every 3rd tome or so, it enters neutral and stays there, will not select 2nd. Once it's n neutral, the only way out is to make sure you're at a sympathetic wheel speed and briefly go back to 1st then back up again, then it engages 2nd every time...........??
Any suggestions ??

Swarb

Post by **masterofinsanity** » Wed Apr 20, 2005 2:45 pm

it worked then? welcome to the forum

sounds like the selector arms worn chap, it's one of those temperamental problems which you need to strip the box down but its a toss between is it worth it or is it really that annoying?

RedexRobB · Post by **RedexRobB** » Wed Apr 20, 2005 3:36 pm

Sure its nothing to do with the fact that it wont go from neutral to second unless its moving? If thats whats happening then that sounds pretty normal to me, theres a mechanism that allows you to select neutral easily, this disengages once the bike is moving

Hope thats the qustion you were asking and that its answered it

swarb · Post by **swarb** » Wed Apr 20, 2005 3:44 pm

No, well unless that 'mechanism' is faulty? Selecting neutral etc when standing still is fine, but it does the same when IT IS moving!!??!!It does feel very similar to when you try and select second standing still, there is just no movement in the lever, its solid if you try and move it upwards, but thats while you're coasting at 30mph with everything you just left at the lights looming large in your crappy mirrors!!!!!

Post by **cargo** » Wed Apr 20, 2005 3:48 pm

Robs right theres a little ball bearing that prevents second gear from being selected unless the bike is moving forward.
This can also happen at very low speeds.
You can if you want just remove the ball bearing and second gear can then be selected fron stand still. I think it's accessable with out too much of a strip down

Post by **cargo** » Wed Apr 20, 2005 3:50 pm

Sounds like maybe the ball bearing is stuck in the can't select second gear position

swarb · Post by **swarb** » Wed Apr 20, 2005 4:51 pm

mmmm, sounds like a good possibility, would certainly explain why it doesn't effect anyother ratio. Also sounds less of a problem to correct, although I still have no intention of doing it myself or paying dealer prices! so if anyone out there is good with a spanner, is in or around medway/maidstone and wants to earn a few quid, give me a shout.

Swarb

Post by **sloweracing** » Wed Apr 20, 2005 5:38 pm

Well what ever you do the engine needs to come out i have a tuner that will strip and rebuild the engine for you cheap but as to find the problem you need to really know what it is once out unless it has worn one of the dogs or has knackered some thing you want know sounds like you just need to strip and then see what you have got.

Hodson Engineering 01732 463658 .Tell him Simon Lowes gave you the number but i reckon you are looking at around Â£100-Â£150 to strip and rebuild the bottom end. He charges Â£50 just to strip a complete engine top to bottom and let you know what is wrong or right if it is visible any way good luck

RedexRobB · Post by **RedexRobB** » Wed Apr 20, 2005 5:58 pm

So this ball bearing, can anyone identify in the manual at all? what page its on and the part etc....

Post by **masterofinsanity** » Thu Apr 21, 2005 8:42 am

http://www.zxrworld.co.uk/images/Lserie ... lector.gif

is it 610 on this microfiche?

RedexRobB · Post by **RedexRobB** » Thu Apr 21, 2005 5:53 pm

Oh dear, no thats not them cos ive just managed to find them in the manual

they are on page 8-15 and they are situated in the 5th gear cog. If you goto the same page and read 'Transmission Disassembly' it tels you, and Diagram 'View AA' on the top right corner shows where they are.

So it definately is an engine apart problem

assuming thats what the problem is at all

http://www.zxrworld.co.uk/images/Lseries/lgears.gif

Here the are, part 600.

Post by **cargo** » Fri Apr 22, 2005 5:32 am

Yes i reckon your right rob thats it.

I've striped the gearbox out of a 93 maybe 94 zxr750 and was able to turn the engine upside down and split the crankcases to get at the gearbox without having to touch the head or barrel.

Don't know if it can be done with a zxr400

Post by **sloweracing** » Fri Apr 22, 2005 4:27 pm

Any help or advice you can allways ring the above number Lawerence would be more than happy to help its not all about racing you will have to take the lump out as the post above then turn up side down and split

GOOD LUCK