ZX/ZZR600 Gearbox overhaul Link

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ZX/ZZR600 Gearbox overhaul Link

Postby BillZZR600 » Tue Sep 05, 2006 1:42 pm

Kindly searched out and posted in another thread by Chaos



http://www.Invalid link see Chaos new post below.
Last edited by BillZZR600 on Sat May 24, 2008 9:51 am, edited 1 time in total.
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Re: ZX/ZZR600 Gearbox overhaul Link

Postby CHAOS » Sat May 24, 2008 2:45 am

The difficult we do immediately, the impossible takes a little longer.

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Re: ZX/ZZR600 Gearbox overhaul Link

Postby BillZZR600 » Sat May 24, 2008 9:51 am

:P
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Re: ZX/ZZR600 Gearbox overhaul Link

Postby frankg » Fri Jun 10, 2011 12:02 pm

ok so are these parts available only from the Dealers or does someone else do a 2nd gear fix kit? Ive read too many stories of ZZR6s being broken up cos of this problem, I guess cos its an uneconomical fix due to cost of parts or potentially buying another engine. There must be tons of good engines kicking about with broken second gears.
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Re: ZX/ZZR600 Gearbox overhaul Link

Postby SteveZZR » Sat Jun 16, 2012 2:06 am

Anyone got part numbers for this job? And an estimated parts cost?
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Re: ZX/ZZR600 Gearbox overhaul Link

Postby frankg » Wed Aug 15, 2012 2:24 am

Right just to add to this post. It is possible to replace the whole bottom of the engine block from one engine to another its EASY all you have to do is remove all the screws from casing and its a straight swap. From there you can also change ALL the clutch and you can also change all the crank shells. It sounds easy, IT IS EASY, once you have the engine out. Word of warning, expect some engine nuts to be VERY TIGHT, a long socket extension or large spanner for extra leverage is recommended. You will also have to remove the oil filter cos there is a screw above it and you cant get a socket near it, you could use a spanner, if you have GOOD ONES. Also should you round a nut, dont forget to use the nearest size imperial socket and hammer the sod onto and over the nuts there soft so it WILL WORK !!

From experience the 600e and 400n use exactly the same blocks same gearbox and looks like the same clutch. I will stick a load of pix on tomorrow of both for some debate. The only difference between the 600 and 400 in the bottom sump as the 400 does not have a hole through for the oil hoses to the radiator, they do look identical from the outside but not on the inside so should someone with a 400 want extra engine coolant add a 600 sump with the hoses and radiator, thats all it is.

Here we have what I believe are the respective parts needed and as you can see NOT CHEAP - including a clutch rod cos this probably contributed SIGNIFICANTLY to a badly worn gearbox in the first place, clonking into gear and forward movement (wearing the gearbox selector mechanism out)

Change drum KA050121 13239 $160
Shift fork KA050118 13140 $70.70
2nd Gear 34t KA050079 13260d $128.87
clutch rod KA050060 13102 $19.70

Here is another article on the problem, although for the life in me I cannot see whats warn on the teeth, Im sure someone else will have more technical knowledge than me and advise on what to specifically look for. http://www.cmsnl.com/kawasaki-zx400_model12783/

It would appear the 400 has 38 teeth, BUT I have also seen the 600 quoted with both 32 and 34 teeth, so god only knows whats right and not and our 400 gearbox is IDENTICAL to the 600 from what I can see.
Last edited by frankg on Mon Aug 27, 2012 12:47 pm, edited 1 time in total.
If your on a restricted license then use your restrictors and dont run the risk of LOOSING your bike

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