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post #1 of 5 (permalink) Old 01-11-2018, 01:19 PM Thread Starter
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Question Hi all + gearbox question

Hey guys, I bought a 1998 ZZR600 (been on a friends before and fell in love with it along time ago) and I've been lurking for a while you guys have all been a tremendous source of help even if you didn't know it.

Shortly after buying the bike I started having A LOT of troubles changing gear, the guy I bought it from already told me that 5th gear was "a little tricky" sometimes which I had taken to mean with a little care and grace it WILL go in...it never did and the seller became remarkably tight lipped over the phone.

As I have a fair bit of mechanical knowledge behind me (admittedly on cars) I read up all the information I thought I needed bought a "new" gearbox which I checked it was in pretty damn good condition and got to work removing the engine.

When I opened it up it was a bit of a mess the dogs were totally screwed the output shaft fork was burned out and overall I'm pretty glad I got to it now before something really drastic happened.

Tl;Dr for question
I'm putting everything back together got the chain on clutch in covers on and oil inter cooler, before I put the oil in I was advised to do the "kawi burp", so I connected all the wires got ready and...the starter motor (I checked it is DEFINITELY the starter motor) is buzzing, checked the idler was seated properly which it is. Soooo took the spark plugs out and the pickup cover and hand cranked the engine and it turned about as freely as I would expect. Then I put it in first gear and the rear wheel turns as I crank it over.

So I pull the clutch in and suddenly the engine is turning...right up until I let the clutch out a little which when done in 1st gear again the engine turns and as I let the clutch out the rear wheel turns a little then suddenly buzzing again...also I cannot get it into 2nd gear the lever simply refuses to go and I am now utterly stuck, as far as I can tell neither the engine nor the gearbox are seized and while i had the engine out with the sump off I hand cranked from the input shaft and all the gears worked just fine.

Also the neutral light doesn't come on but I know it is in neutral because the wheel is turning yet again buzzing starter motor.

I REALLY don't want to take the engine out again simply because of the huge hassle it was to get it in and out because I am doing this all on my own, so anyone got any ideas? I'm thinking ill probably have to take the sump and/or clutch off just to make sure the forks are still in properly and didn't jump out of position behind my back causing it to jam under load but aside from that I'm just stuck and a little fed up.

Last edited by nauroticdax; 01-11-2018 at 01:22 PM.
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post #2 of 5 (permalink) Old 01-11-2018, 01:33 PM Thread Starter
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It's also worth pointing out that with it in 1st gear and the spark plugs out I cannot turn the rear wheel
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post #3 of 5 (permalink) Old 01-11-2018, 03:09 PM Thread Starter
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..I feel like such a goddamn moron, it was the clutch lever switch...which i had always assumed was broken because I've never tried to start my bike in gear before and in neutral it dosen't do anything...I THOUGHT that it was just a cutoff (like if you tried to start with the kill switch in stop) I didn't realize that the starter motor would make noise like it was TRYING to turn over...

literally just popped the damn clutch cover off was getting all ready to strip it down but gave it another try and sure enough the engine and wheel were both turning, after derping around for a minute it suddenly occurred to me...pushed the clutch lever forward (because ofc the cable is disconnected and sure enough it started buzzing at me

If I had checked the neutral line (which was attached but had a really bad connection) from the start id be done by now...

....Words cannot describe how much i want to scream right now
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post #4 of 5 (permalink) Old 01-13-2018, 12:50 AM
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That was a really long story of how you solved your problem,

HOWEVER, good experience and if it ever happens to another forum member, you may be able to help them out!
Best of luck and welcome to the forum!

Yes We Have Shoes In Kentucky... We Also Have Motorcycles.

-KentuckyKawi
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post #5 of 5 (permalink) Old 01-13-2018, 04:03 AM Thread Starter
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Quote:
Originally Posted by KentuckyKawi View Post
That was a really long story of how you solved your problem,

HOWEVER, good experience and if it ever happens to another forum member, you may be able to help them out!
Best of luck and welcome to the forum!

yeah I thought best to leave it up because I've never heard of starter motors doing that kind of thing usually they either turn or dont.

Aside from some small leaks here and there and a misfiring problem (pretty sure its either water in the carb or #2 spark plug is done so I'm picking a set up in an hour) its all good gearbox went all the way up and all the way down with no problems at all I cant wait to take her out for a decent run.
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