[jeffy6514]

Wondering if anybody has any knowledge of this problem that I am having, at the end of last summer I bought a ZX9R '98. Seemed to be in good shape, bought it fairly cheap, the only problem it had according to the previous owner was that it needed a clutch. After getting it further looked at it turned out that it needed tranny work, it only seemed to act up when you throttle down in third gear, so needing a winter project I decided to tackle it myself. After removing the motor and splitting the crankase I could see metal shavings but observed absolutely no damage to the transmission, upon removal of the entire unit I did however notice that the side of the shift fork that was against third gear was worn down to almost half, that explained my metal shavings. So my first question, does anyone know what would cause the shift fork to do this, I suspect that the bike was laid down so it could have come dislodged.
My second problem, I bought an entire transmission, with shift drum, shift forks, gearchange mechanism..etc on Ebay. The installation went well, however after putting everything back together, I tried to put the clutch back on and in the end the pressure plate wouldnt go on all the way in, I spent the whole day trying to figure out what was wrong, I finally noticed that the input shaft was about a half inch longer than the the one I took out, I couldnt believe it, so, I cut the new input shaft right down to the exact mm, machined the end and everything went on great. However, I needed to know why my new input shaft was longer, so, after scouring through every post on this site, I found one little section that mentioned that a ZX6R had the exact same transmission as a ZX9R, except the input shaft is longer. Unbelievable, so I am thinking that I have a ZX6R transmission in my bike, does anyone think that if I keep this like this that the ZX6R tranny will fall to pieces when I start riding this bike, thanks in advance.

 

[ninjayorkie]

I know some of the transmissions are different, most folk try to fit a E or F transmission as the gears are better spaced so the gears engage better, I hear the shaft is slightly longer and something else has to be fitted but can't remember.
I would asume that what you've done should be ok.

 

[spdingtkts]

The 98/99's had trans issues due to a design flaw.

98's were worse.

99 they used some revised parts that improved it but did not fix.

00 on they fixed the design flaw and the trans stop having problems. Also the 00 and up have an improved design shift drum and this should be used if replacing the drum.

The difference in the shaft length due to getting a different year transmission. Its been too long so I do not remember exactly but I do remember that Kawi used a shorter shaft on some years and a longer shaft on the others.

 

[shiphteey]

Hey there. We've got a good 98/99 trans but its in the motor so we'd have to remove it if you want it. $200 shipped if you're interested. If you want you can also send me some pics of what you received and we can help verify what it is or isn't. We may be able to make it work for your application depending on what you are working with.

A.

 

[spdingtkts]

The only way I would install a 98/99 transmission would be if were modified to use the 2000 and up configuration. Gast was offering this as an option when sending in a trans for undercutting.

2000 and newer transmissions can be found on ebay for very reasonable prices.

I remember we swapped a trans into a 9R and ran into the different length shafts. It was a long time ago so forgive me if my memory is wrong but I think that all the parts are the same EXCEPT for the clutch pull rod. They are different lengths to accommodate the different shaft lengths.

98/99 uses rod part # 46102-1420
00 and up uses rod part # 46102-1425

All you need to do is swap the above pieces for whatever trans you are using.

 

[jeffy6514]

So, I either have a Tranny out of a 2000 and up, or its an E or F version. The only difference that I could notice was the input shaft was longer by almost half of an inch. I machined it down to the exact mm and soft filed the end nice and smooth and put everthing back together, now the motor is sitting on my bench waiting to be put back into my bike in the spring. I really dont want to spend another $300.00 dollars on Ebay and tear the crank apart again, I hope this works.

 

[Kob9625]

Hello, I recently purchased a 2001 ZX 9R with 30,000 miles on it unmolested I never really beat on by an older gentleman. I just service on it and now the shift lever is very tight and will not go into third gear. Does anybody ever had any issues like this.? What do I do next? Please help

 

[ninjayorkie]

Yes, its a common problem and an easy fix, strip and clean the footpeg pivot point and ensure the best position on the shaft into the gearbox for the best positive movement, this is slightly to the rear. I did a picture guide of this over on zx-9r.net. there are lots of other good information posts in that thread.