mistergrumpy
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| posted on 21/2/08 at 12:21 PM |
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ZX9 Gearbox Improvement
Saw this on another forum. An interesting fix on the C1 gearbox. Starts about 10
boxes down.
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coozer
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| posted on 21/2/08 at 01:20 PM |
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Great fix if you've got a CNC lathe or similar gear turning device... 
How about just making a new selector drum that moves the selector over a bit further, or make the gears thicker so the dogs engage a bit more??
1972 V8 Jago
1980 Z750
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badding
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| posted on 21/2/08 at 01:25 PM |
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MMMM very interesting, I haven't got any problems so far.I think the engine itself is bulletproof, it's the gearbox, but with this
conversion it seems that the engine would be the same as an E model...
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larrythelathe
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| posted on 21/2/08 at 01:37 PM |
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interesting good find
I would be worried about machining the gears tho'.
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tegwin
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| posted on 21/2/08 at 01:48 PM |
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SO would I...
Arnt the gears macined and then case hardended.....Harder than a hard thing!
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Would the last person who leaves the country please switch off the lights and close the door!
www.verticalhorizonsmedia.tv
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MikeCapon
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| posted on 21/2/08 at 02:25 PM |
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I did (almost the same thing) last year on a Suzuki gearbox (450LTR quad). Same problem to start with. Insufficient engagement of the dogs, strangely
enough on 3rd gear as well. On the Suzuki there is a central boss which bears against the circlip. All we did was to turn off 2mm from the boss and
add a 2mm thick washer on the other side. If anything it was more difficult to sort as the 450 LTR is a vertical split motor. The other related
problem we had on this motor was the flat plate on the selector shaft prevented full selector movement. We just ground a bit more material out and it
worked fine. The gearbox didn't last forever but that's not a surprise when you look at quad riders  and the size of their boots 
Edited to add: Machining was not a problem. Done in and old parallel lathe, dry (no suds). I believe that the gears are probably induction hardened,
hence the bit we machined was soft(ish).
[Edited on 21/2/08 by MikeCapon]
www.shock-factory.co.uk
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ch1ll1
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| posted on 21/2/08 at 08:38 PM |
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hi try this page might help you out
www.ksrc-au.com/html/fixing_a_zx9r_gearbox.html
paul
[Edited on 21/2/08 by ch1ll1]
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mistergrumpy
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| posted on 21/2/08 at 09:53 PM |
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Good one that Ch1ll1 seems a lot easier that one. I've only got the gearbox left to go wrong now so I can't wait to do that now
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ch1ll1
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| posted on 22/2/08 at 06:42 PM |
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can in handy when i did mine !
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mistergrumpy
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| posted on 22/2/08 at 06:44 PM |
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Unlucky mate. Out of interest did the rebuild go well and did you use an E model box like in the guide?
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