ZZR250 1st gear problem

A friend has managed to drop my ZZR250 by getting off and letting go without
putting the stand out first.

The bike came down on the left side and took her down with it. She is okay
but the bike is not as lucky.

Cosmeticly there are a few minor scratches on the mirror, bar end and
exhaust. The real problem is the bike won't shift into 1st anymore. I can
shift up to second (rolling to get passed the posi-neutral) and beyond but
shifting down the lever doesn't seem to click down but still changes down
all the way to neutral.

Anyone have any ideas on what's damaged in the transmission based on the
symptoms?

I'm thinking the shift arms that operate the drum may be bent, which would
mean removing the clutch or the drum is damaged which would involve
splitting the case. I'd attempt the clutch removal myself but not the
splitting the case.

Skuz
'91 ZZR250

 

Actually, splitting the case on a ZZR engine is not that big of a job.

Alternatively, if it's really stuffed, I know someone with a ZZR250 engine
they want to flog off.

But, now that my spamming is over, are you sure it's not just the shift
lever being bent? That's the most likely cause.

If it's not that, then it's possible that you've done something nasty to the
selector shaft, or something like that, and you'll be needing to take the
clutch cover and clutch off (be carefuly, the retaining nut on the clutch
basket _will_ require a rattle gun to get it off. Don't use a torque wrench,
you'll break the basket).

Once you've got the clutch out of the way, you'll be able to remove the
selector shaft then and see what the problem is.

 

Does the gearbox go through all gears?

Does it feel like the lever doesn't return as normal

I suspect that the detent Spring may be worn & fell off

Daron

 

Have a look at the rod that connects the foot gear shifter back to the
engine body. It's got thread adjustments both ends. This could have
somehow got bent or adjusted so far down that there physically is not enough
travel to select 1st any more. On my old ZZR250 this rattled out of
adjustment whilst I was ridding, giving the same symptoms you describe.

Cheers,

Paul

 

An expensive way to learn that yours shouldn't be the bike people have their
first-ever riding experience on.

More information... have you tried shifting further up? Into 2nd, 3rd, 4th
etc, then back down again?
If you can shift up, but not down all through the box, then the problem's
likely to be on the outside (bent gearshift linkage, as suggested, or the
pedal...), but, and I doubt this is too likely, if you can shift down from
4th to 3rd, from 3rd to 2nd, and from 2nd to neutral, but not to first, then
the problem might be internal.

Again, the latter is Loch Ness Monster-sighting unlikely. Bikes have landed
on their left sides from 10 feet up in the air and not damaged their
gearboxes. Yours should be fine.

 

Is the lever not just bent and interfering with something else?
That's the first thing to check. Often the click down into first
needs the lever to move a bit further than the others, I know if
I bend the gearlever on the XLV it fouls the bashplate and won't
shift into 1st ...

Maybe, but there's generally a few other bits first, the gearshift
shaft isn't attached directly to the shift drum, it'll go to
another widget first. It's more likely that that widget is bent.

BT will know, he's an expert at throwing away those engines

-----sharks

 

Can't you just take it to the mechanic and present her with the bill? It
would be easier to do if you're sleeping with her ...
- sanbar

 

Thanks All. Got it sorted.
The lever was fouling on the the part that the side stand spring hooks on
to. I can't believe I didn't see it straight off.
It was as Sharkey suggested, first gear needs that little bit more travel as
it changed up and down through the other gears without a problem.

Hehe. The friend is my wife's sister who is having a hard time affording to
get her own bike back on the road, hence practising for her Ps on my bike.

Skuz
'91 ZZR250

 

good news!

-----sharks

 

Bastardo! >:-|

But yes, I think it's worth taking a good look at the external shifter
linkage first. Maybe even remove it and see if you can engage first
using a pair of pliers?


BTH

 

Teachers pet!!

Hammo

Wanna split some TT cases with me?

 

Yeah, sure. What's wrong with it?

-----sharks

 

I had a ZZ-R600 that did that once...

Nev..
'03 ZX12R
'02 CBR1100XX

 

Gearbox, 3rd is naughty.

Hammo

 

But I don't drink TT...


Postman Pat

 

mates DR250 fell over and the gearlever contacted a rock and snapped off
a lug in the gearbox and wouldn't change up or down , stuck in neutral

this was down Heathcote way , you would know the place IK where all the
dirtbikes
hangout , fortunately this happened on a major trail,and the 4x4 went down
and got it out

also fortunate it was still in warranty , but took a while for parts to
arrive

 

I have a case of VD, interested?

Hammo

 

There's a warranty against falling over? Cool!

Gary