Zzr600-e 2nd gear

[Tonyg1987]

So, my bike has low mileage and is in fairly good condition for it's age and I have not come across this...yet, fingers crossed
I was just wondering, theoretically if I were to get the dreaded jumping out of 2nd gear problem that seems to be common with the zzr600, how much roughly would it cost to get fixed? I wouldn't be able to do any of the work myself because I haven't got a clue when it comes to that sort of stuff, so it would have to be put into a garage. Would it be cheaper to have the gears rebuilt or just have a brand new gearbox fitted. Just wondering with parts and labour what it might cost, hopefully not more than the bike is worth haha.

[mentalboy]

I wouldn't worry too much about it until it becomes an issue, it will probably be rather expensive to have a garage strip it down to rectify that kind of problem.
Assuming your post wasn't badly worded and it is already an issue you can help yourself with smooth moving off and avoiding popping wheelies.

There are plenty of other things on an older Zed that will keep you occupied - suspension bushes, shockers, fork seals, valve clearances, keeping brake units in tip top condition, etc, etc. Just keep an eye open for issues as they crop up and fix them as they do. Keeping up with routine maintenance/cleaning will help considerably.
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Make mine a Corona.

[redeem ouzzer]

If you had to use a garage it wouldn't be viable in terms of cost. However if it's not doing it right now I wouldn't worry.
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Be a REAL MAN!

[DrSnoosnoo]

My e is at 60k and no sign of the "2nd gear issue".

Providing you're not trying hamfisted wheelies you shouldn't get the issue anyway.

On the ZZR group there aren't many reports of this 2nd gear myth that seems to float around. Not saying it has never happened, just that it doesn't seem as common as the myth suggests.
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I'm Sam; Northern, Ginger, Lover
Did have: '95 ZZR600 '83 CG125 '97 ZZR1100 '15 Hypermotard 821 SP Do Have: '10 ZX10R

[Kickstart]

Hi

I have heard (but no evidence) that the 2nd gear issue was largely sorted on later E models, and was an issue on the D and early E models.

As a problem it isn't meant to be too hard to fix, but you are still looking at a fair amount of money. Caused by worn dogs on 2nd gear, hence just those parts that need replacing. Think it can be done without splitting the crankcases fully on the ZZR engine.

That said, a lot seems to come down to how they are treated. The ZZR always seemed to have a hefty clunk into 2nd gear if pushed, and suspect doing that repeatedly will screw it up. Ridden normally 2nd gear engages very smoothly.

The ZZR we had managed at least 60k without any sign of a 2nd gear issue. One we bought spares or repair (a year or 2 older) hadn't even managed 30k before 2nd gear wasn't usable.

All the best

Katy
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Tonyg1987]

[jjdugen]

Just the way things work out but I must have had ten or more ZZR's through my hands. From immac low milers to post 60,000 milers looking sad and neglected. None have had the slightest of gearbox problems. Even the tired ones still went like a scalded cat, but, as mentioned, needed all the running gear seriously looking at.
Great bikes... still!
Ride and enjoy, not much else out there as good (for the money, well. maybe the CBR600's, certainly not the 600 yams, they DO lunch gearboxes and not an easy fix either).
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The CBR900RR has been sold. Aprilia Falco worms its way into my heart.
Try Soi 23 on Amazon for a good read.... Self promotion? Moi?

[johnsmith222]

Similarly to kickstart, I have also heard that it's a problem with D and early E models (with nothing to back it up).

Personally, I wouldn't bother worrying too much about it. I'd just ride it, and come up against the problem if it happens.

If it happens, I'd learn how to sort it yourself, and spend the money you would have given to the garage on tools.