2nd gear slipping

KevlarPants · Nova Slayer Joined: 21 Jan 2005 Karma :

'94 zzr 600, 35k miles.

When I shift up into second and put the power on the gear slips, like it hasn't quite engaged. The bike lurches, once or twice until the gear catches properly. At least that is the best way I can describe it. Once it has engaged/caught it is ok then. Although I don't tend to stay long in second as this lurching is not nice.

The bike has been doing this for the last year, but recently it has almost caught me out, once nearly high siding me (off a roundabout, wasn't fun).

So I spoke to a mechanic and he said that as it is only one gear it is unlikely to be the clutch, i.e. second gear cog is knackered.

Short version, thats going to be expensive to sort out.

He laid out three options.

About ten hours labour to get the engine out and 'split' it, and see whats what in the gearbox and go from there.

Option two, get the engine out and put new engine in. This would probably work out a bit cheaper.

Third option, flog it and get another bike, probably the cheapest option.

So, I'm just looking for some opinions here I guess. The bike cost me 1500. With the way the numbers are stacking up trading in is the cheapest option.

However, I could probably live with it for now and just stay the hell away from 2nd as much as possible.

Thing is I quite like the bike. Its my first 'big' bike and it goes like stink off a stink shovel.

Any thoughts?

instigator · Super Spammer Joined: 19 Oct 2004 Karma :

I would look for a replacement engine and THEN sell it. ZZR600 is apparently known for it's gearbox problems. It seemed like the perfect bike for me until I heard about that. Mad

It may be your first big bike but that is no reason to hang onto it. Go forth and try something else. Thumbs Up

0ddball · World Chat Champion Joined: 15 Jul 2005 Karma :

Bear in mind that because it's a common problem, any replacement engine you get might have the same problem. In fact it could be the reason the donor bike was broken for parts.

chris1-4-7 · Renault 5 Driver Joined: 21 Dec 2006 Karma :

My old man has had a zzr in the past. Kept it for over 2 and a half years. Never had any transmission problems. Spannermonkey has also put forth a good comment. How it may have been the reason in the first place. Wink

Chris(Brum)

bunglehaze · Brolly Dolly Joined: 12 Oct 2006 Karma :

Im in the same predicament and to be honest I love the ZZR but my logical thinking is telling me to sell it for peanuts and just get a different bike, apparently doing the replacement is not that difficult but from my experience so far the hard part is finding the replacement parts which on your bike (same year as mine) would be:

Drum : 13239-1176
Forks: 13140-1154
13140-1191
Top output dog: 13260-1478
2nd output dog: 13260-1379

As some have said it may be that any 2nd hand part you buy would be just as bad so you need to check over the drum for the damage before buying (or get the breaker to email over a photo if mail order) I have been offered replacement engines which in my opinion are just not viable for the price people want for them (offered one APPARENTLY 4000 miles on a 2000 plate - slightly suspicious as weekend warriors who keep miles low dont usually buy sport/tourers price=£300 on a bike that cost me £900 hardly seems worth it)

So right now its a toss up between replacing and tidying up the bike then selling, selling as is and having to spend a fair bit more on a replacement or repairing the transmission, respraying and keeping it for another season.

In my case I have dropped it so there are a fair few scratches that make it look untidy which is making me lean more towards getting rid of it as is and buying a zx6r instead Smile

cheers

leigh Very Happy

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Odie · World Chat Champion Joined: 24 Jul 2004 Karma :

Its not the drum (selector drum) that goes its normaly the "dog teeth" that slide across to engage with the next gear in the box, These engage with the next gear to transmit the drive to the next cog / gear.
If some-one has been slamming it into that gear they can go, also if some-one likes to give a bike some stick in a certain gear to much that can cause it, also if they not been case hardened properly during manufacture they can go and some gear boxs are just shit!
Had to do a complete box on zzr1100 that had a second gear problem so it could just be down to a bad design by kawasaki!
Selector forks can go, if they go you normal cannot get a gear at all. (selector forks transmit the movement from the selector drum to the gears)
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You are so ugly when you were born the doctor said "I?m gonna drop it, if it falls is a rat, if it flies is a bat."

bearwood.beckham · Renault 5 Driver Joined: 02 May 2006 Karma :

Could it be the clutch? Has it been replaced in the time you've had it or by a previous owner. 35k is alot on a clutch and gearbox.

Odie · World Chat Champion Joined: 24 Jul 2004 Karma :

veeeffarr · Super Spammer Joined: 22 Jul 2004 Karma :

This is what puts me off of Thundercats and ZZR's although they're perfect for me Sad

bearwood.beckham · Renault 5 Driver Joined: 02 May 2006 Karma :

Odie · World Chat Champion Joined: 24 Jul 2004 Karma :

bunglehaze · Brolly Dolly Joined: 12 Oct 2006 Karma :

bearwood.beckham · Renault 5 Driver Joined: 02 May 2006 Karma :

KevlarPants · Nova Slayer Joined: 21 Jan 2005 Karma :

Thanks for the replies guys.
My garage are going to have a look on monday, and we'll take it from there.
While the idea of a new(er) bike is attractive, I might have to live with this for a bit.

cheers