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.