01 zx9r trans/shift problems like no other i've found.

[juiced_9r]

first of all, i'd like to say hello to everyone here on xzf, i'm a long time lurker, first time poster..this site is #1.....!!

anyway, i have a problem that i just cant figure out i've searched for weeks and called numerous shops with no avail......

i have a 2001 zx9r that runs like a top...13,xxx miles all stock except a yosh slip on,.. i have encountered a few(maybe 3) false neutrals and sometimes when i would try to upshift the bike would stay in the same gear i tried to shift out of (2nd to 3rd, trans would stay in 2nd, or 4th to 5th it would stay in 4th) you get the idea...with another try it would shift just fine..i thought with that and the false neutrals i could have been me getting lazy on the shifter...but its not! now the problem is....if i start the bike while its cold and in neutral i can shift to 1st gear but when i try to upshift to second it goes to neutral, then with some wiggling up and down and getting pissed of and stomping on it ang jerking up on it it will change...THEN after i ride it for a mile or so it will shift like it did before, which isnt perfect either...i have a hard time believing its the shift fork(s) because the problem is not limited to just 1st and 2nd, its during all shift attempts...downshifting is fine, not a glitch!! i tried to adjust the shifter down but that didnt help a bit...i rode 100 miles one day last week and it wasnt too bad, brought that bastard home washed it and now its doin this!! i bought a factory pro shift kit and am still awaiting its arrival from ebay(20 bucks shipped, i thought i would try it) ..now i'm starting to second guess that that is even the problem...

and by the way, it does not pop out of gear at all and never has....
any help or info would be awesome!!!

[Shifty1]

Sounds like it's time to tear into the tranny. This is definitely not an adjustment issue...something is bent, broken or chewed to shit. Good luck.

[Nal]

Difficulty Shifting
When you need excessive clutch lever pressure to shift gears, it may
indicate either a clutch problem or a transmission problem. If the
clutch is at fault, you’ll notice symptoms such as grinding gears when
you shift into low or first gear. As we discussed earlier, in most cases
if the clutch is at fault, a simple adjustment will solve the problem. If
the transmission is at fault, you’ll notice difficult shifting between
other gears while the motorcycle is moving. This problem may indicate
a bent shift fork or seized gear on the transmission shaft. When a
shift fork is damaged, it will no longer fit properly in the grooves of the
gear. To fix this problem, you’ll need to disassemble the engine
and replace the shift fork. When a gear has seized on the transmission
shaft, the problem is usually caused by a lack of proper lubrication.
As with the shift fork, you’ll also need to disassemble the engine to
repair the problem.

Inability to Shift Gears
Occasionally you’ll find a machine that shifts into one gear, but won’t
shift into the next gear. This problem is often caused by the shift return
spring which returns the shifting lever to its original position. You
can usually repair this problem by replacing the spring. The spring
is usually located near the clutch assembly. In most cases, you won’t
need to completely disassemble the engine to repair the problem.

[juiced_9r]

[quote=Nal;208968]Difficulty Shifting


thanks for the info! its not a clutch problem, i just took it out and checked it and it looks new, no wear on the basket either.. and no extra force is needed to pull the lever...it works like it should! and there is no gear grinding!!

like i said before, i have a hard time believing its the shift fork, i really dont see all 3 bending at once and then the bike shifting easier after i ride it for a minute...once it's in gear its good but having to try for 10-20 seconds in between shifts sucks!

it seem like if i could pull up on the shifter just a little more it would go, but then again it only goes so far...and it is moving as far as it should!
there is a little resistance on the shifter as there should be and it feels normal, it just dont like to shift and when it does it means business! it goes in gear with a forceful clunk
idk! i was just trying to get some opinions and maybe a few educated guesses before i get ass hole deep into something i dont know much about...lol

[zaneyzrex]

could the the shift mechanism behind the clutch basket... could be the piece attached to the drum is coming loose.... check all that as you work your way into the cases....

[juiced_9r]

Originally Posted by zaneyzrex

could the the shift mechanism behind the clutch basket... could be the piece attached to the drum is coming loose.... check all that as you work your way into the cases....

cool,THANKS! im gonna start on it monday, the engine is ready to come out now but i dont have time to fool with it...i'm hoping it's the detent spring,micro bearing or the shift star....but i am not that lucky! the new shift kit will be here soon, i hope! the piece you speak of that could be loose on the drum....are you refering to the shift star? i'm hoping for an easier-than-not fix....but like i said...MY LUCK!

edit: the only thing that leads be to believe it MAY be the shift mechanism is the false neutrals i've experienced and what i've read online...just trying to put all the info together to try to get a game plan...

[zaneyzrex]

ya if ya wanna call it that... lol it is the star that attaches to the drum..... if its loose it will spin on the end of the drum instead of moving the drum..... good luck

[juiced_9r]

ok, well it's apart.....i done a quick inspection and so far everything looks good, i'm gonna do a little more research and check specs on everything i can find specs on... i'm still curious to see what the new shift kit will do for it.....i'll update as i find new info!

[Nal]

[quote=juiced_9r;208981]

Originally Posted by Nal

Difficulty Shifting


thanks for the info! its not a clutch problem, i just took it out and checked it and it looks new, no wear on the basket either.. and no extra force is needed to pull the lever...it works like it should! and there is no gear grinding!!

like i said before, i have a hard time believing its the shift fork, i really dont see all 3 bending at once and then the bike shifting easier after i ride it for a minute...once it's in gear its good but having to try for 10-20 seconds in between shifts sucks!

it seem like if i could pull up on the shifter just a little more it would go, but then again it only goes so far...and it is moving as far as it should!
there is a little resistance on the shifter as there should be and it feels normal, it just dont like to shift and when it does it means business! it goes in gear with a forceful clunk
idk! i was just trying to get some opinions and maybe a few educated guesses before i get ass hole deep into something i dont know much about...lol

that's why I posted the second paragraph , also sometimes it's the way you shift, some bike are odd when shifting, mine goes into false neutral sometimes when I shift the lever up to slow or do it in a lazy manner, sounds like what you described, but that's on mine

[Nal]

try to change the way you normaly shift and see how it works out

[juiced_9r]

Originally Posted by Nal

try to change the way you normaly shift and see how it works out

it dosen't matter what i do, it still wont shift usually i have to pull up on it really hard by hand.... i'll get er fixed....one way or another...i found a complete engine/trans for 700 obo....i'm thinking hard on it!.....thanks again for all the help guys!

[zaneyzrex]

careful on buying used........THEY ARE SELLING IT FOR A REASON ........ good luck...

[juiced_9r]

Originally Posted by zaneyzrex

careful on buying used........THEY ARE SELLING IT FOR A REASON ........ good luck...

its a local guy selling the setup, he bought it for one of those midget type car things...lol

added info: rotate the shifter shaft on my bike...and the little mechanism moves up and down but the shift star/drum dont turn......

[zaneyzrex]

ok then either the star is loose (theres a bump on the star that sits in a hole on the drum) maybe its turned enough to tighten up. also make sure the spring is in place on that same assembly.......

[juiced_9r]

grrrr......

[juiced_9r]

ok, well i hung around the house today and the ups man finally came with my shift kit!! whooooo hoooo, i broke out the impact, took the clutch basket out, took the shift mech. out, took my parts outta the box and had an EFFIN cow...right in the middle of the garage....I HATE EBAY! the idiots sent me a clutch kit for a damn 03-07 yz250.....WHAT IN SAMS HELL AM I GONNA DO WITH THAT? GRRRRRRRRRRR! so yeah, i'll probably have to send that back and wait another 11 days or more for the correct parts, since i'm sure they were sent to someone else........damnitdamnitdamnit!




ANYONE NEED PARTS???????????????? LOL

[zaneyzrex]

bummer.... since youre there check the shifter mechanism and make sure the star is tight/spring is good etc.....

[juiced_9r]

Originally Posted by zaneyzrex

bummer.... since youre there check the shifter mechanism and make sure the star is tight/spring is good etc.....

iv'e looked over the mechanism a time or two, everything looks good,(as far as i can tell) it just seems like the whole mechanism isn't moving enough to turn the drum as much as it needs to turn, there is no binding anywhere in the trans, at all...with the pan off i have spun the sprocket with a low speed drill and shifted the trans through the gears 1-6 and back several times and sometimes it will go through the gears just fine and other times the drum just don't go far enough and it hangs in neutral, i can take 1 finger and give the drum a little nudge and it goes right to the next gear....

:

[juiced_9r]

Originally Posted by juiced_9r

iv'e looked over the mechanism a time or two, everything looks good,(as far as i can tell) it just seems like the whole mechanism isn't moving enough to turn the drum as much as it needs to turn, there is no binding anywhere in the trans, at all...with the pan off i have spun the sprocket with a low speed drill and shifted the trans through the gears 1-6 and back several times and sometimes it will go through the gears just fine and other times the drum just don't go far enough and it hangs in neutral, i can take 1 finger and give the drum a little nudge and it goes right to the next gear....

:

i knew i should have bought another gsxr...........

[zaneyzrex]

Originally Posted by juiced_9r

i knew i should have bought another gsxr...........

lol why so ya could loose second gear on it too.....