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post #1 of 19 (permalink) Old 06-04-2012, 07:50 AM Thread Starter
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ZX11 no third

So i feel like i have read about this before but, i just got my zx11 on the road and discovered theres a problem with 3rd gear. All the other gears are perfect, but when i shift to third its like im in neutral. I can shift past into 4th and be fine but i wanna fix this. Im new to this bike so can anyone point me to the right explanation. If i were to diagnos i would think a clutch plate, or maybe just the transmission needs a swap. But what do i know haha im a newb. All help is appreciated.
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post #2 of 19 (permalink) Old 06-05-2012, 06:25 PM
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Most likely third gear is gone. Do it yourself and youre out of a weekend and couple of gaskets. A shop will want between 1800-2500 plus parts and you will get your bike back in a month if you are lucky or longer. If you can remove and replace the carbs without trouble then you can probably do this repair with the aid of a shop manual and a couple of cheap torque wrenches from Harbor Freight or the like.
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post #3 of 19 (permalink) Old 06-05-2012, 06:59 PM Thread Starter
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By third being out im assuming you mean replace the transmission, and what all gaskets do i need? thanks
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post #4 of 19 (permalink) Old 06-05-2012, 08:28 PM
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Its most likely a bent shift fork. If the gears look good, you do not have to replace the entire tranny.

There is a ZX11 tranny on eBay, Did you even check out my link?

Here is a shift fork for sale $53.00, which appears to be the price for a brand new one.

http://www.ebay.com/itm/Kawasaki-ZX1...sories&vxp=mtr



It appears to be the shifter side fork.


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Last edited by Blainethemono; 06-05-2012 at 08:43 PM.
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post #5 of 19 (permalink) Old 06-06-2012, 06:08 AM Thread Starter
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Yes i checked out your link, im gonna tear into and check the fork first before i buy a new transmission. Or would i be wiser to go ahead and replace it while im in it?
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post #6 of 19 (permalink) Old 06-06-2012, 09:03 AM
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Cole, you wont know that until you open the case and inspect the gearbox. Then you will post massive pictures for us and request our input.

Gears could be just fine, and you may only need a new fork which is pretty cheap compared to a gearbox.

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post #7 of 19 (permalink) Old 06-06-2012, 09:35 AM
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can you make the shift fork stronger since you have it out somehow,dont know if you can get if forged or somehow treated to were it will be stronger.the reasone i ask this is cause if you can, maybe it will be harder to bend it...just a thought.???

2000 zx1100
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post #8 of 19 (permalink) Old 06-06-2012, 09:45 AM
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I never made it but I believe the forks can be replaced without splitting the engine. It surely is a tight fit though.

From all the reading I made, it's more than likely the gears that are worn out than a fork that is bent.
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post #9 of 19 (permalink) Old 06-06-2012, 12:43 PM Thread Starter
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Alright well, i plan on going ahead and opening up the engine tommorow and i have a replacement transmission and 3 forks. I figure id rather do this all at once rather then multiple times. As for a thread thats helpful for this, the most helpful one ive found is catastropic failure by zxfixer.
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post #10 of 19 (permalink) Old 06-08-2012, 04:25 PM Thread Starter
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So i have the engine out and open. No chunks floating around. Im on the clutch now. Does anyone know a good way to get the clutch out without a special tool. As you all probably can tell im new to this.
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post #11 of 19 (permalink) Old 06-08-2012, 04:39 PM Thread Starter
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so this is where i am now. It looks clean so far. Opinions? Guesses when i would shift it into 3rd it would be like i was in neutral.
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post #12 of 19 (permalink) Old 06-11-2012, 03:29 PM
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Cole
You need to get the oil pan off, the assortment of tubes removed under the oil pan and then remove the oil pump to get a good look at the gears. Look for the 3 projections off of the side of the gear, called dogs. Look for damage on those and also the receiving gear has slots that the dogs slide into. There may be damage on those as well. Also inspect your replacement tranny for similar issues. Label and tag everything on disassembly. Take lots of pictures that you can refer back to. Even with a service manual an organized teardown saves a lot of work.
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post #13 of 19 (permalink) Old 07-16-2012, 08:23 AM Thread Starter
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so i know its been a while on this but, my transmission looks fine. All gears are good, all dogs look good and clear. Im thinking it for sure is the forks.
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post #14 of 19 (permalink) Old 07-16-2012, 01:06 PM
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I think its possible to do this on a ZX11 engine. Hand turn the gears and go thru shifting motions.... Start in first then shift up until you hit third and observe how the gears engage. Do they travel far enough and insert themselves into the dog hole?

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post #15 of 19 (permalink) Old 07-17-2012, 01:59 PM Thread Starter
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I tried that and everything seems to be in working order. What are the signs of a bad shift fork?
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post #16 of 19 (permalink) Old 07-18-2012, 08:17 AM
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Scuff marks, burnishing and/or polished-scrape marks on edge of fork

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post #17 of 19 (permalink) Old 07-18-2012, 07:26 PM Thread Starter
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Ok, i am seeing signs of that forrrr sureeee. So tommorow i will replace any that look damaged at all with my new ones i bought off ebay. Thanks for the advice. Ill probably run into more issues as i replace and rebuild so talk to you all soon.
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post #18 of 19 (permalink) Old 07-18-2012, 07:56 PM
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Quote:
Originally Posted by trophytaker308 View Post
can you make the shift fork stronger since you have it out somehow,dont know if you can get if forged or somehow treated to were it will be stronger.the reasone i ask this is cause if you can, maybe it will be harder to bend it...just a thought.???
Stop kicking the shit out of the shifter and you don't have to worry about it.

╭∩╮(︶︿︶)╭∩╮
Quote:
Originally Posted by 185EZ View Post
The rear tire on my 14 is low on air.
So I was thinking of rebuilding the motor.
If that doesn't correct the problem, probably replace all the fairings
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I ride a Honda.
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post #19 of 19 (permalink) Old 07-19-2012, 10:42 AM Thread Starter
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haha trust me, it wasnt me that did the damage to this bike. I bought it wrecked and have just about fixed it. But i do believe the previous owner was rough on it.
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