Question about 1992 kawasaki ZZR 1100

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I have a 1992 zzr 1100 it goes into 1st gear then back to neutral but will not go into 2 3 4 5 6 gears ? can you help.

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  • clivepassing Sep 23, 2009

    The bike has not been used for 5 years and was ok then!
    when you put it into 1st it goes in with a clunk so may be it is the clutch !



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Assuming the clutch is operating properly the problem sound like it lies in the gear case, possbily a worn or bent shift fork, sorry but it sounds as if you will need to split the cases.

Posted on Sep 23, 2009

  • tberan1 Sep 23, 2009

    Hopefully the clutch alone will do it for you> if he just sat for some years the gear case should be fine. I believe that bike has a hydraulic clutch? If so bleed it out and place in new fluid (careful not to get it on the paint) If the clutch still does not work you may have to rebuild the cylinder or slave cylinder.

    Good luck with it!




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hi,2 possible causes,1-if the bike has remote linkages to the gear shift,check that the shaft that the gear lever itself is pivoted on,is well lubricated and moves freely,they sometimes have a habit of filling  with road grime over time and this will cause them to stick or become quite heavy in operation,2-and this requires removal of the crankcase cover to repair,the return spring on the shift drum has lost its strength and needs replacing,i hope that it is the first option as that is easy to fix,the second option not quite so easy and a lot more expensive if you have to have it done in a shop..hope this helps...cheeers

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Have a problem with my zzr 1100 nutreral light it is not eluminating so could someone help me solve this problem

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Jun 23, 2009 | 1992 kawasaki ZZR 1100

1 Answer

Zzr gear box

I have been a bike mechanic for over 10 years and never seen this one before. The only thing I can even think of is a broken shift fork. This would let a slider gear wander freely and potentially engage a gear while the bike is already in a different gear. This would account for the rear wheel lock up. The 'tight spot' would probably be a torqued and twisted shaft resulting from the lock up.

The repair will be major surgery on the tranny. Personally, I would replace all shafts, all gears and all shift forks. You don't know and can't just look and see what stress has been put on any individual gear. I would hate to see you put in a few gears, put the engine back in the bike, then find a stressed gear dropping a couple of teeth the first time you hit second. To put it another way, get a new tranny and a new chain. The chain was stressed also. Sorry about the bad news.

Ask the dealer what the cost would be to replace the entire tranny but not the clutch. Now Google ' salvage motorcycles kawasaki ' and see what an entire used engine would cost. Chances are the engine swap that you can do yourself will cost less than the dealer's repair of the current tranny.


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