Fixing 3:rd gear on ZX9 -98 - undercut?

Discussion in 'Motorbike Technical Discussion' started by Henrik, Feb 22, 2004.

  1. Henrik

    Henrik Guest

    Problem I had with the bike is 3:rd gear jumping out and it got worse
    by time.

    I have now split the crankcase and disassembled the two transmission
    shafts. I was almost certain to find wear on gears and dogs on the
    gears but they look ok. At least what I can see. I have never worked
    on a bike transmission before but with Haynes manual it was easy to
    take it apart.

    Can someone tell me what I'm looking for here? Dogs and gear-tooths
    looks fine. 3:rd/4:th gear look darker than the other, almost like it
    got hot or something. Maybe it should look like this. The dogs "hook"
    in to the other gears like they should but they tend to go apart if
    you put some force to them (they don't lock themselfs together
    harder). Do I need to replace 3:rd gear pairs even if they look ok?
    Could the problem be in the gear change drum or the three forks?

    Hope someone can help me out here :)

    Best Regards,
    Henrik Olofsson
    Henrik, Feb 22, 2004
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  2. Henrik

    Fwoar Guest

    Usually the forks bend - It does't need much to band one - missed gear etc.

    If there is there any markings ( scoring ) on any of the selector forks -
    they need to be replaced.
    Same with the gears on both shafts

    Tis a common zx9 problem
    Fwoar, Feb 23, 2004
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