Help! - Kawasaki ZX6E Transmission Problem

I'm having a problem with the transmission on my '95 ZX6E. It will shift
from neutral into 1st or 2nd gear, but not into 3rd or higher. I
disassembled the tranny and replaced the shift forks, the shift fork shaft,
shift drum, and the gear change lever return spring. I also inspected the
transmission shafts and all of the gears for any warping or broken teeth. No
damage was found there. I'm at a loss as to what the problem could be. I
checked with the mechanics at my local Kawa shop (Raleigh, NC) and the only
suggestions they had to give would be to replace all of the gears and
transmission shafts or get a complete engine from a salvage yard. Both of
those ideas are beyond the reach of my checkbook at this time. If anyone can
help figure this out, it would be greatly appreciated!

Rodney Reeves

 

This may be completely out in left field but do you have a "positive neutral
finder" on your ZX6 like I have on my EX500? Earlier this summer my bike
stopped shifting altogether (stuck in first) and after disassembling
everything myself and then inspecting with a mechanic friend of mine for a
looooong time, it turned out there are three ball bearings on the
countershaft that serve this purpose (PNF). I removed the bearings and
everything works fine now--of course I don't have a PNF anymore, but who the
heck cares, my bike works! I don't know all that much about engines but
just maybe this could help. Good luck,

Scott

 

I do have a PNF on my bike. Wasn't sure if there would be a safety issue in
operating without it. Will try doing without the PNF & see if the problem
goes away. Thanks!!