No gears

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Discussion

chapiness

Original Poster:

27 posts

199 months

Sunday 27th April 2008
quotequote all
Any ideas please ?
Clubsport ZZR1100.Poor downshift had to keep selecting twice, now seems to have only one gear possibly 3rd or 4th. All external components intact.
Am I looking at a full rebuild on the gearbox? engine still runs fine.
any input or advice welcome.
Chris

RobC

967 posts

290 months

Sunday 27th April 2008
quotequote all
Sounds like a bent selecting fork, if you can get the car high enough drop the sump and you'll be able to see the gearbox to see what has happened.

BertBert

19,534 posts

217 months

Sunday 27th April 2008
quotequote all
when this happened to me (exactly the same symptoms) it was gears in a mess. Sev dogs and teeth chewed. Rebuild needed. You'll have to have a look and see.
Bert

chapiness

Original Poster:

27 posts

199 months

Sunday 27th April 2008
quotequote all
Thanks for the advice.
Whatever the problem is am I right in thinking its engine out and strip down rather than something that can be done with the unit still in the car ?
If it is gears, is there the possibilty of debris in the engine causing further damage . Who did your rebuild bert and how much?
To be honest I am a bit brutal with the gearbox, being more used to mk9 Hewlands so I think I have resigned myself to the worst!
The car is fitted with a flat shifter up, and down, whilst the upshift is great the down shift was always poor. The other strange thing is with the flat shifter connected the car looses all power after 3 laps (lydden] with the symptom of fuel starvation. disconnect the flat shifter and no problems .
I only use the car for sprints and trackdays so its great for sprints ...

BertBert

19,534 posts

217 months

Sunday 27th April 2008
quotequote all
I had a huge (3600) rebuild as the engine and case were knacked too. I used POwertec. Many people on here have alternative recommendations! Nothing wrong with pwertec apart from the cost!
Bert

RobC

967 posts

290 months

Sunday 27th April 2008
quotequote all
When my old ZZR gearbox exploded I picked up a second hand bottom end on ebay for £150, bolted my top onto it and job was a good'un and total bill was about £250. If you are in our neck of the woods (Gloucestershire) sure Neil at CMS will do the engine for you - http://www.coriniummotorsport.co.uk/

As for the other problem, could be the alternator isn't man enough to power the paddle shift and isn't charging the battery properly. What is the voltage on the battery before and after a race, wouldn't mind betting the voltage is down considerably after the race

chapiness

Original Poster:

27 posts

199 months

Thursday 22nd May 2008
quotequote all
Well, I very nearly sent the unit back to radical as the labour for a 'box strip was 340 plus gaskets 100 plus parts plus vat. Now that didn't sound too bad . The pain was getting it there 2x 300 mile trips or carriage at 2x £100
Finaly found a highly recommended bike shop who does race bikes, charges £40 an hour plus all parts etc . stripped down and found .......... just a broken detent spring ! The bad news is he can't find the missing bit , we won't know how much is missing til the new one arrives . So far I think I've been quite lucky so I think a total strip to check for the missing bit would be warranted.

Rob, we had pondered over the eletrics but half dissmised it because we had run a camera which didn't cause any simmilar problem . I was thinking of rigging a voltmeter in just to check voltage when running , thanks for the thoughts .

Final question , the front sprocket was loose and is quite worn . The guy at the shop says he tried a kawazaki one but the offset was miles out . the car runs a reverser motor which I am not putting back on. I thought i had read on here that the bike ones fit? any input welcome .
Thanks


RobC

967 posts

290 months

Thursday 22nd May 2008
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Front spockets, the C and D engine sprockets are different. One is dished and one is not. However I can't for the life of me remember which is which, however if the one you've got doesn't fit then you need the other one biggrin

chapiness

Original Poster:

27 posts

199 months

Thursday 22nd May 2008
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Thanks, How do you tell a C from a D engine ?

RobC

967 posts

290 months

Friday 23rd May 2008
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iirc the engine number will give the game away, the bike shop that you took the engine to should have the info (its on the parts list) If not give me the engine number and I'll find out for you

Prawn

99 posts

248 months

Friday 23rd May 2008
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Engine number will not always work as you can put the C output shaft into a D engine if you use some of the other gerbox bits.
May have been rebuilt with either in the past (as we found on the old clubsport)
The output shafts are different lengths, ie the need for the different sprocket, like Rob though cant remember which is which.

As rob says if one does not fit you need the other.

chapiness

Original Poster:

27 posts

199 months

Saturday 24th May 2008
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New spring arrived, got about an inch missing from the old one . My head says strip the lot and find it ....... but my wallet says different

chapiness

Original Poster:

27 posts

199 months

Monday 2nd June 2008
quotequote all
Got my engine back , the missing part of spring found in the depths of the gearbox. The Bill ?............ £183
Next outing Lydden again 21st

RobC

967 posts

290 months

Monday 2nd June 2008
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Nice one