Question about 1990 kawasaki ZZR 600

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Will not engage 4th gear going up or down the box.bike has done 45000 miles but has no other problems i have checked linkage and all seems ok

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It can be anythone of a number of things, stripped cog, worn shaft, worn selector drum. Unfortunately all of them inside the casing. To get at it entails removal of the engine and a complete disassembly. DIY is not recommended if you're not knowledgeable on the inner workings of a bike engine or at least have a good repair manual, since you'll be diassembling that motor in totality.

Posted on Jul 15, 2010

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Posted on Jan 02, 2017

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Hi,

This might be because of the gear box problem. By any chance, did your car face flooding? In such cases, please drain the gear box and replace it with new gear fluids. Also, check if you go in low speeds, you might be able to engage it with ease. Please come back to me if you feel this doesnt solve your issue.

Regards,
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The bike has a bent shift fork or two. This is a MAJOR repair and best done by a knowing mechanic.
The motor comes out of the bike then turned upside down for removal of the bottom case. The clutch, shift shaft, flywheel, electrics, gears and gear shafts gotta come out so you can get to the bad fork. There's much more but the idea is that you are better off having the shop do the repair unless you have experience, are extremely mechanically inclined, and have the tools. The bad news is that a shop is going to charge around $1200 to $1500 for the repair. Some shop mechanics also repair bikes at home. If you find one, you can save $200 to $400 or so. Sorry to be the one to give you the bad news. The diagram below shows how a shift fork moves a slider gear left and right to engage different gears. A bent fork will not fully engage a gear.

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