Transmission repair advice needed...... : Kawasaki ZX Forums: Kawasaki Ninja Forum

ericzx7 · 01-03-2008, 11:42 AM

I have a 95 zx7 , and it slips out of second gear into neutral under any load. I have aquired replacement shafts, gears,and shift forks. I have a workshop manual(HAYNES). I have never replaced transmission shafts before, and I was wondering if some of you who have experience with this could give me some advice. I would like to know , for instance, what gaskets and other odds and ends I will need to purchase before tearing down the bike. And also if there are any quirks that the ZX7 might have, that arn't listed in the manual(tips,tricks,special tools etc...) that I should be aware of. Any help would be appreciated. I'd like to get the tranny fixed now, as I already have the tank off so I can have it cleaned out and I can do some welding on it. This would be a good time to do the tranny , and get everything ready for spring.

ericzx7 · 01-22-2008, 01:24 PM

Really? All this knowledge here and no one has any input at all? Come on guys, I know some of you can build these motors with your eyes closed. Any info at all would be appreciated. Like things to look out for when splitting the cases , any tips at all. Thanks .

ericzx7 · 02-16-2008, 04:45 PM

One more try. Does anyone have anything helpfull to say on this topic?

nandez71 · 02-20-2008, 08:04 PM

dude from anything i have ever heard or seen, dealing with any transmission. rebuild is a pain in the anus. i bought my wife a zx6 that was lipping out of second. and after i priced the repair at a local repuyable shop. it was cheaper and made more sense to get a engine/tranny combo off ebay. less miles on the motor and no shift problems. i know this aint what you was wanting to hear but thought i'd chime in with what i went through.

Saint_Matthew · 02-20-2008, 08:57 PM

The transmission repair IS the most difficult repair out of anything you could repair on a bike. I've never done one on a 4 cylinder engine, but I tried to rebuild a KX125 a few years ago. I spent way too much money on a complete gasket set and all the tools I needed to split the cases. Taking the top end apart was nothing compared to what's involved in just opening that thing up. The one thing I suggest to get is someone who's done this before.

n8dagr8 · 02-26-2008, 11:35 PM

Quote:

Originally Posted by Saint_Matthew

The transmission repair IS the most difficult repair out of anything you could repair on a bike. I've never done one on a 4 cylinder engine, but I tried to rebuild a KX125 a few years ago. I spent way too much money on a complete gasket set and all the tools I needed to split the cases. Taking the top end apart was nothing compared to what's involved in just opening that thing up. The one thing I suggest to get is someone who's done this before.

You would have better luck stealing food from a polar bear that hasn't eaten in several months...

If you have never rebuilt a transmission before, or even seen the insides of one, you are better off taking it to a mechanic or buying a "new" engine. just my two cents...

http://www.zx-12r.org/Motorcycle_inf...ShortBlock.jpg
the bottom half is the trans...

n8dagr8 · 02-26-2008, 11:43 PM

Quote:

Originally Posted by nandez71

dude from anything i have ever heard or seen, dealing with any transmission. rebuild is a pain in the anus. i bought my wife a zx6 that was lipping out of second. and after i priced the repair at a local repuyable shop. it was cheaper and made more sense to get a engine/tranny combo off ebay. less miles on the motor and no shift problems. i know this aint what you was wanting to hear but thought i'd chime in with what i went through.

You bought your wife a ZX6!?!?! My wife won't ride by herself, but I like it better that way, he he he...

jscho600rr · 02-27-2008, 06:35 AM

pull out the motor flip it upside down and pull the bottom half off drop in the new trans and forks and deff a new shift barrel and follow you hynes manual and put it back together it is not hard for some one with some machanical abbility

ericzx7 · 03-04-2008, 03:53 PM

Thanks for all the replies. I do intend on doing the repair myself. Am enrolled in a bike mechanics course starting in August, and I guess I'm not patient enough to wait to learn it in class. Silly, I know, but I figure now is no time to wuss-out. I think I can handle it, I was just looking for some tips. You know. Things they don't tell you in the manual. jsho600rr, that is exactly what everyone else local has told me. Thanks to all for your input! I'm open to ANY usefull info.

slim1100 · 03-04-2008, 05:05 PM

dont strip heads or threads..... be sure ...very sure before turning, good luck

Jarrod · 03-04-2008, 06:11 PM

make sure you have all new circlips and washers for the shafts, and make sure you put the circlips in right.......with the sharp edge facing away from the direction of torque. and just make SURE you put everything together absolutely correct, or the first time you ride it you will junk the trans.

Kawi_T · 03-05-2008, 01:08 PM

I would recommend sending the trans to a place like MRE in Florida to have the trans inspected and the gears undercut. I had one done for a KZ1000 a few years back. I thought is was very affordable at under $400. This way when you go through all the trouble of splitting the cases and doing the trans, you know the parts going in are good. How do you know the used trans you bought wont also jump out of gear?

n8dagr8 · 03-06-2008, 01:04 AM

Quote:

Originally Posted by Kawi_T

I would recommend sending the trans to a place like MRE in Florida to have the trans inspected and the gears undercut. I had one done for a KZ1000 a few years back. I thought is was very affordable at under $400. This way when you go through all the trouble of splitting the cases and doing the trans, you know the parts going in are good. How do you know the used trans you bought wont also jump out of gear?

and he hits another one on the head...

NOX · 03-07-2008, 12:07 AM

Send the tranny to Mark at RnD. They do the best work, bar none........, if it must shift, no matter what........, they will make it do it....., not cheap, but the best........

Located in Florida. Let me know if you need a number. I don't even think they are listed, they stay that busy..., they do all the trannys for VnH, Muzzys, velocity, etc.........