Z1000A1 FORK SELECTOR REPLACEMENT

[z1000puddin]

My zeds gearbox issue is getting worse.
Jumps out of second gear, more often now.

Gets bloody arse twitching especially if it happens whilst overtaking

I know that this is quite a common fault, my question is, can this be done with out splitting the crank case ??

If I just pull the sump of & outer gearbox cover, is it an easy fix ??

Thanks in advance

Stu

[z1bman]

yes it is possible to remove the selector forks without striping the crankcases but you will still have a problem with the worn dogs on the gears . my advise would be to split the crankcases + do the job properly . replacing just the bad selector is only half the problem?

[z1000puddin]

z1bman
Thanks, that thought did cross my mind.

Looks like a winter strip down then

cheers
stu

[Garn 1]

'Puddin, If you find it isn't in the selectors forks and you do have to split the crank-cases, you could find that the 4mm washer (known as thick washer) may have been unwittingly replaced with a slimmer washer. This was the case when I had a disaster a few years back.

This 4mm washer is next to the ball-bearing on the sprocket (output) shaft. Now if it Ok, Inspect the second gear oval slots and the engaging pegs on the 5th gear, both of which are close to this ball bearing, on this output shaft.

Usually, the culprit will be the rounding of the pegs on the 5th gear, which will not allow full engagement in the slots of the 2nd gear to drive it. You may need to replace this gear. Unfortunately, the roundness (wear) on the pegs cannot be inspected from the sump!

RegardZ.

[z1000puddin]

Thanks Guys for the input,
It looks like I will have to split the cases in order to identify the area of the problem.

Ah well the old girl is due off the road at the end of the month, so it will keep me busy in the garage

Cheers

stu

[Garn 1]

A good time to renew the timing chain, if you split the crank-cases. although you don't really have to remove the head and barrels to do this gear box job.
RegardZ.