extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 22, 2009 08:30 AM
Stuck in 4th Gear
Well something finally went wrong with the bike. Stuck in 4th gear. Can't go up or down.
I've been pledged with fine metal shavings in the oil each oil change from day one. I think the shavings are aluminum, bright colored and the magnetic drain plug doesn't pick them up. The bike just turned 10K
I'm thinking that a shift fork finally went south, if they are made out of aluminum.
Any thoughts?
I'm going to stop by the dealer today ans see what he says.
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'pilot
  
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NINJA12
Needs a job
Posts: 3310
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posted October 22, 2009 09:41 AM
I would go with shift fork or the rods the slide on.
Can you rock the bike and get it to shift?
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Rideharder
Zone Head
Posts: 821
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posted October 22, 2009 10:01 AM
 Edited By: Rideharder on 22 Oct 2009 18:04
Look at the shifter and grab it and see if you can yank it toward you may be the lock pin came loose..
Lay down beside the motorcycle and look directly at the shifter you can get a clear view of the washer and lock pin.
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extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 22, 2009 10:21 AM
Rocking the bike does nothing.
The retainer ring and washer look OK, in tacked.
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'pilot
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Rideharder
Zone Head
Posts: 821
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posted October 22, 2009 10:43 AM
Very unusual, wish you the best man!
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INTIMIDA2OR
Needs a life
RED rider!
Posts: 13081
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posted October 22, 2009 11:54 AM
Wow that's a strange failure. Does the shifter have any action or does it stay locked up or down?
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'06 Passion Red ZX-14
*Lee*
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extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 22, 2009 01:13 PM
Shifter goes up and down with spring tension, but feels like there is nothing connected to it.
It's at the dealer now so I will be waiting for a call in a few days.
Let you guys know what's going on.
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'pilot
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LAB3
Needs a job
Posts: 2977
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posted October 22, 2009 01:52 PM
Still in warranty.....Right? Shifting forks are Not aluminum, defferent alloy much harder.
Metal shavings in trans shafts and locked up or worse. My guess by what you have said
and done. Suprised it would Not rock out of gear pulling back on back wheel. Really locked
something up. Any loud sounds before it would not shift from 4th? (drive dog tabs snapped) from shat seziure. pieces of tabs loged in trans gears. Early FJ1100 Yamaha
did this had a factory recall. problem was fixed FJ1200 tuff bike.
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extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 22, 2009 02:40 PM
Edited By: extrapilot on 22 Oct 2009 22:42
No noise before, just down shifted to 4th going up a hill, went to next downshift to make a turn and nothing engaged after that.
I've been looking at the shifting mechanism under the clutch basket where the shift cam is for the drum, could be a problem there or at the end of the shift rod, same location, Looks like allot of parts there that could easily be broken.
The service manager told me that the shift forks are made from a harden aluminum material, could that be correct?
I know engines very well, used to rebuilt them for a production engine re-builder, but never worked on a motorcycle transmission, or even had a opportunity to open a MC engine.
Thanks for the info.
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'pilot
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extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 22, 2009 02:41 PM
Still under warranty, thankfully.
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'pilot
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Shane661
Needs a life
Posts: 11494
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posted October 22, 2009 02:44 PM
Shift forks are steel.
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extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 22, 2009 03:55 PM
Edited By: extrapilot on 22 Oct 2009 23:56
Well that puts a wrinkle in the idea to where the aluminum particles are coming from.
Any idea?
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'pilot
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INTIMIDA2OR
Needs a life
RED rider!
Posts: 13081
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posted October 22, 2009 04:31 PM
Engine cases are aluminum 
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'06 Passion Red ZX-14
*Lee*
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stcalder
Novice Class
Posts: 32
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posted October 22, 2009 05:57 PM
i had this problem on my 06. happened going into 4th at the strip. anyway got it to a friends garage and pulled cluth and basket. started looking and thought that the spring on the shift forks was weak or broken. pulled shift shaft out and spring to find that the spring was alright. the forks would not fully move so thought that they might be bent. they are a close tolerance fit. we were looking up the part on bike bandit and i was spraying the forks with wd40 and cleaning them when a small piece of clutch fiber came out from between the forks. after that came out the forks worked as advertised sliding back and forth smoothly. havent had a problem since.
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lowered 1.5 in rear 3/4 in front w/strap. PCIII. Brocks TI sidewinder. roaring toys ext. set all the way back Muzzy fan. shiftlight by boostbysmith.
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INTIMIDA2OR
Needs a life
RED rider!
Posts: 13081
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posted October 22, 2009 10:04 PM
Geez clutch fiber? That was an easy fix! I'm gonna have to remember that one!
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'06 Passion Red ZX-14
*Lee*
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Flame On
Needs a life
Fuel Air & Spark
Posts: 17104
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posted October 22, 2009 10:40 PM
I would think damaged shift fork also for the gear jam must of been scraping something aluminum wrong and finely gave out
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77 RD 400
80 GS1000 GT
06 ZX14
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extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 23, 2009 02:24 AM
quote:
i had this problem on my 06. happened going into 4th at the strip. anyway got it to a friends garage and pulled cluth and basket. started looking and thought that the spring on the shift forks was weak or broken. pulled shift shaft out and spring to find that the spring was alright. the forks would not fully move so thought that they might be bent. they are a close tolerance fit. we were looking up the part on bike bandit and i was spraying the forks with wd40 and cleaning them when a small piece of clutch fiber came out from between the forks. after that came out the forks worked as advertised sliding back and forth smoothly. havent had a problem since.
Can you actually see the shift forks with just the clutch basket removed?
Or did the case have to be split.
Thanks for the info guys
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'pilot
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stcalder
Novice Class
Posts: 32
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posted October 23, 2009 03:46 AM
sorry its not the fork reading the wrong part. bike bandit has a pic.
http://www.bikebandit.com/houseofmotorcycles/kawasaki-motorcycle-zx1400a6f-ninja-zx-14-2006/o/m17997
the spring is part number 92144. sorry about that. its part of the shift shaft.
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lowered 1.5 in rear 3/4 in front w/strap. PCIII. Brocks TI sidewinder. roaring toys ext. set all the way back Muzzy fan. shiftlight by boostbysmith.
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extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 23, 2009 06:23 AM
OK ......Thanks for the clarification on that.
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'pilot
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Flame On
Needs a life
Fuel Air & Spark
Posts: 17104
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posted October 23, 2009 06:33 AM
Can you actually see the shift forks with just the clutch basket removed?
Or did the case have to be split.
Case split
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77 RD 400
80 GS1000 GT
06 ZX14
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KikonZX14
Pro
Novice
Posts: 1813
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posted October 23, 2009 07:14 AM
http://www.bikebandit.com/houseofmotorcycles/kawasaki-motorcycle-zx1400a6f-ninja-zx-14-2006/o/m17997
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Feel the need for SPEED2007 ZX-14 Black with Red Flames (Helibars, Sliders, Yoshimura TRC Ti 4-2 Slip Ons, Fender Eliminator, Zero Gravity SR Windscreen, Custom Heel Guards , Speedohealer V4, Pazzo Levers -soon to come: Flies out / PCV w/A/T kit and later 16T sprocket)1990 Honda Steed (Japan model same as Shadow)1993 Kawasaki Vulcan EN 500 (gone as I trade it in for the ZX-14)Santiago, Chile, South America
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Swiftkart
Expert Class
Posts: 349
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posted October 23, 2009 08:22 AM
Edited By: Swiftkart on 23 Oct 2009 16:25
Happen to me once, all it was on mine was the outer snap ring behind the shift peddle that holds the shaft in place had come out of the groove because of excessive play and allowed the shaft to move enough so it wasn't turning the shift drum, I just put mine on the lathe and cut a deeper groove and put a thicker washer inplace to eliminate problem.
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2006 ZX14, Brock CT-Meg, PC, ignition module, E85, 214 lbs suited, 8.96@152.32 1.46 60'
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INTIMIDA2OR
Needs a life
RED rider!
Posts: 13081
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posted October 23, 2009 09:10 AM
quote:
Happen to me once, all it was on mine was the outer snap ring behind the shift peddle that holds the shaft in place had come out of the groove because of excessive play and allowed the shaft to move enough so it wasn't turning the shift drum, I just put mine on the lathe and cut a deeper groove and put a thicker washer inplace to eliminate problem.
Wow very cool to know! I hop I never have to use that trick lol.
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'06 Passion Red ZX-14
*Lee*
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swiftnet
Novice Class
Posts: 88
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posted October 24, 2009 09:51 AM
QUOTE"I just put mine on the lathe and cut a deeper groove and put a thicker washer inplace to eliminate problem" UNQUOTE
Must be nice to have a frickin' lathe laying around ; )
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Keeping the rubber side down since 1984
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extrapilot
Expert Class
2008 ZX14
Posts: 155
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posted October 31, 2009 07:35 AM
quote:
i had this problem on my 06. happened going into 4th at the strip. anyway got it to a friends garage and pulled cluth and basket. started looking and thought that the spring on the shift forks was weak or broken. pulled shift shaft out and spring to find that the spring was alright. the forks would not fully move so thought that they might be bent. they are a close tolerance fit. we were looking up the part on bike bandit and i was spraying the forks with wd40 and cleaning them when a small piece of clutch fiber came out from between the forks. after that came out the forks worked as advertised sliding back and forth smoothly. havent had a problem since.
Update:
Apparently this was the same problem that the dealer found with mine.
Something was stuck between the shifting arm and the cam (star) for the shift drum.
All is well again.
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'pilot
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