ZX9R Sticking gears - C2 (1999) 19k

[TheGazWaz]

Hi everyone. Really concerned about this. The problem started this morning on my way to work.

Basically the bike will go up through the gears fine but intermittently doesn't want to shift back down. It's like instead of a gear shift there's a space on the lever.

So I'm in 5th gear, approaching a roundabout, 50mph, Drop down to 4th, 40mph, go to drop down to 3rd. nothing but a space. I keep pressing, clutching in and out but it just won;t go. Selects up fine and back down to 4th. Finally gets 3rd and does the same thing until I finally get second by which time I'm at the side of the road waving people past while frantically trying to get first.

Any ideas guys. I'm pretty desperate here. The bike has never missed a beat. It never slips out of gear. The engine sounds fine. No grinding when in gears. When I pull away it will be fine for a while then it does it again.

Please help

Cheers

Gary
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Went like this.. 43 years old(2013) decided to do CBT to get a 125 for new job. Bought 2011 YBR, loved it for three months then hated it because it was too god damn slow. Did DAS 4 months later then bought RF600 Loved it, sold it bought Bandit 1200(K3). EFFIN lOVED IT. Wanted something a bit more sporty so got Triumph Sprint ST 955i (53). Not sporty enough so now on my GSXR 1000 K3 and absolutely love it. 1 year down the line, nearly died way too many times on this bike. Sold it. Had a 6 month break. Missed biking so now, Aug 2019 have a 1999 ZX9r. What a beauty she is too.

[Bhud]

Interesting problem. I did a quick Google search, and apparently others have reported similar issues. This web page is interesting:

https://www.ksrc-au.com/html/fixing_a_zx9r_gearbox.html

And there are a lot of other reports on the web to read.

From the sounds of it, all other things being good, you will need to remove the engine and split the cases to see what's wrong.

[stevo as b4]

Apparently all C-series ZX9R's do this, as do all early R1's lose 2nd gear, and all R6's munch up their cylinder linings too. And let's not forget all RGV250's destroy their power valves and let the pistons smash them to bits.

[TheGazWaz]

I can get every gear and there's no slip or jumping out. It's just downshifting like something isn't returning to accept the next shift.
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Went like this.. 43 years old(2013) decided to do CBT to get a 125 for new job. Bought 2011 YBR, loved it for three months then hated it because it was too god damn slow. Did DAS 4 months later then bought RF600 Loved it, sold it bought Bandit 1200(K3). EFFIN lOVED IT. Wanted something a bit more sporty so got Triumph Sprint ST 955i (53). Not sporty enough so now on my GSXR 1000 K3 and absolutely love it. 1 year down the line, nearly died way too many times on this bike. Sold it. Had a 6 month break. Missed biking so now, Aug 2019 have a 1999 ZX9r. What a beauty she is too.

[stinkwheel]

I just looked and they have a similar gear selector shaft pawl to a GPZ500. I've had two of these fail in the way you describe. it has a couple of hooks on a bit of flat plate on small bendy springs that grab the selector drum and rotate it. if the hooks wear round, it doesn't always grab the next notch on the drum.

Beore you do anything though, make sure you are taking your foot totally off the lever before going for the next shift. You wouldn't be the first person to have a gearshift problem that was their new boots making them leave their toe on the lever (do you have new boots?).

On a GpZ, the selector is under a cover of its own behind the front sprocket and you can wiggle it out with the engine in the frame. No idea about a ZX9R though.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[DJP]

[1198]

On my ZZR the pin that is used to hinge the left footrest has an annoying habit of moving up just enough to obstruct the gear linkage.
I don't think it's this, but it's worth a check before you start ripping engines to bits?

[trevor saxe-coburg-gotha]

The issue is well-known and potentially very easy to cure. It is usually NOT the gear box and may be down to this:

https://i.postimg.cc/0ywddfBp/zx9-gear-change-peg-recess.jpg

There are stories of entire gearboxes being replaced and the problem remaining - until eventually being chased down to that one peg.

In short I think there is room for cautious optimism.

Go here for more information on this and other aspects of the C2:

https://www.zx-9r.net/viewtopic.php?f=48&t=22019

NB you may need to join that website in order to access the relevant content - but if you're running a nine it's invaluable and there are still a fair few active and very knowledgeable owners there, even though the bike is now about 20 years old.
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"Life is a sexually transmitted disease and the mortality rate is one hundred percent."

Mobylette Type 50 ---> Raleigh Grifter ---> Neval Minsk 125

[TheGazWaz]

Thanks for the replies everyone. Certainly a few bits to check there.

One thing I did notice that very morning was that my gear selector seemed higher than the last time I was on the bike. To the point that I had to lift my foot off the peg to go down.

The sprocket where the gear mech is attached to is all in order. No slippage there. I nipped it up a bit just in case.

My chain is not only about due a change but it's also a bit slack. I'll sort that out. Clutch seems to be pulling in OK at the arm but I'll see if I can adjust it a bit tighter.

Do gears just fail like this? I mean with out any progressional warnings?

I've also sprayed a sh1t load of WD40 around where the gear selector shaft goes into the case. I was pretty corroded up round there where I've been riding when there's salt on the road. Maybe something is sticking there.

I'll let you know how I get on.

Cheers again

Gaz
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Went like this.. 43 years old(2013) decided to do CBT to get a 125 for new job. Bought 2011 YBR, loved it for three months then hated it because it was too god damn slow. Did DAS 4 months later then bought RF600 Loved it, sold it bought Bandit 1200(K3). EFFIN lOVED IT. Wanted something a bit more sporty so got Triumph Sprint ST 955i (53). Not sporty enough so now on my GSXR 1000 K3 and absolutely love it. 1 year down the line, nearly died way too many times on this bike. Sold it. Had a 6 month break. Missed biking so now, Aug 2019 have a 1999 ZX9r. What a beauty she is too.

[Sister Sledge]

Gears can indeed fail in many areas. Earlier versions of the engine in mine (DRZ400) is known for gear teeth fracturing off.
Let's hope yours is the easy foot peg fix.
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CCM 404 DS

[TheGazWaz]

Looks like I got Lucky,

I striped down the footpeg and gear select mechanism. It was pretty crudded up. Gave it a thorough cleaning then plenty of grease.

Also did an oil and filter change.

Bike runs beautiful again. I took it for quick spin that ended up lasting 2.5 hours and it didn't miss a beat. All gears selecting smooth and positive.

I am sooooo happy.

Cheers all for your help especially to trevor saxe-coburg-gotha. I feel I've just dodged a bullet.

Gaz
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Went like this.. 43 years old(2013) decided to do CBT to get a 125 for new job. Bought 2011 YBR, loved it for three months then hated it because it was too god damn slow. Did DAS 4 months later then bought RF600 Loved it, sold it bought Bandit 1200(K3). EFFIN lOVED IT. Wanted something a bit more sporty so got Triumph Sprint ST 955i (53). Not sporty enough so now on my GSXR 1000 K3 and absolutely love it. 1 year down the line, nearly died way too many times on this bike. Sold it. Had a 6 month break. Missed biking so now, Aug 2019 have a 1999 ZX9r. What a beauty she is too.

[Bhud]

Lucky

[trevor saxe-coburg-gotha]