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PostPosted: Sat May 08, 2010 5:11 am 
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Hey all, just succesfully installed a 2003 Z1000 transmission into my 1998 ZX9R with amazing results. Its like a brand new bike, no more clunky shifting, its nice and smooth and you have to hold on tight when you are in third or fourth gear. If anybody is planning on doing this let me know, I can give you a step by step description of how I did it.
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PostPosted: Sat May 08, 2010 3:42 pm 
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Ok, Here goes. I bought a 1998 ZX9R a year ago, not knowing anything about the real bad gearbox design. Immediately third gear was gone and fourth gear was on its way. It clunked heavily into every gear and it was not real fun to drive. However, the motor ran great and the bike looked real sharp.
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So I decided to try and fix it, I am not a motorcyce mechanic but it is amazing what you can do with a Haynes manual.
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So first of all I tried all of the lazy fixes, I just changed the shift forks, shift rods and drum, and that didnt work at all. I ordered another Transmission off of Ebay which was supposed to an E series Transmission but it ended up being a C2 Transmission which ended being worse. After taking the motor out and pulling all the gear apart it was amazing how much damage there was. Shift forks were done, Circlips were all bent and worn, Gear dogs were all rounded and all of the steel balls in the fifth gear which make up the positive neutral finder were all gone. Lets just say I got ripped off from my purchase on Ebay.
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So at this point I decided to try and find an E series Transmission off of Ebay. However, through some of these forums I noticed that a few guys had used Z1000 Transmissions with good results, so I decided to investigate that a little more. It turns out that the 2003 to 2006 Z1000 Transmissions are almost identical to the newer ZX9 Transmissions that do not have the bad design. So that is the route I decided to take. And sure enough on my first search on Ebay there was a guy selling a 2003 Z1000 transmission complete with Input Shaft, Output Shaft, Shift Drum, Shift Rods and Forks.
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So I bought it right away. So to do the swap you have to do this, The Input Shaft is a straight swap, you just drop it right in, keeping in mind if you have a 1998 ZX9R like me, the Input Shaft is shorter so you have to purchase a new clutch lifter (part #46102-1425) from your local Kawasaki dealer, you also have to use the Z1000 shift drum and Z1000 shift rods. Everything else from your ZX9R can be used, the gearchange mechanism, the shift forks are all the same, as long as they are not damaged (I bought new ones). Also note that your gear change rod is thicker on the Z1000 so you definitely have to use the ZX9 one. Now onto the output shaft, the shaft is longer on the Z1000 so you have to take all of the gears off of the ZX9 shaft and put the Z1000 gears onto that. At first I thought that it would be really hard but it was actually pretty easy.
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Number one most important thing to do is use all new Circlips, very important. Plus, you will notice on the newer Z1000 output shaft that there is an extra groove in the shaft, this is were the splined locking washer goes, and this is what the C1/C2 Transmissions didnt have and this is the reason why they were crap.
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There is also two splined bushings as well, the C1/C2 only had one bigger splined bushing. So all have to do with these locking washers is grind off the locking bits on the one of them( I grinded the locking bits off of washer 29) and then you can slide both locking washers onto the the older shaft with no problems. I then installed the three steel balls into fifth gear, and with the output shaft standing straight up I carefully lowered the gear onto the shaft and when the balls were lined up with the grooves on the shaft I just poked them into the grooves with a pin, if the gear is unable to slide back up it is good.
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And here is the finished product.

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So with the bike back together, I have been driving it for two days now and what a difference, it drives like a brand new bike. My friend has a 2005 ZX10R and he says that it shifts better than his does. It goes through every gear smoothly
and has no problem finding neutral. And Fast, fast, fast, it is so nice having power back into third and fourth gear. Well worth the time and effort, if anyone wants more info on this feel free to ask. And remember, its impossible to do this without a Haynes manual.
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EDIT: yorkie. Worth a quick look at this thread also. http://www.zx-9r.net/phpBB2/viewtopic.php?t=42575


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PostPosted: Sat May 08, 2010 6:01 pm 
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Nice one fella glad it worked for you.I did this conversion using a 2006 z1000 transmission in my C2 and the gearchange is spot on. My zx9 gear box was crunchy and on inspection the gear dogs showed a lot of wear on 3RD & 5TH on input shaft.The z1000 is a 953cc using zx9r crankcase and has same gear ratios. The transmission should work 2003-2006 z1000 !


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PostPosted: Sat May 08, 2010 6:28 pm 
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The polished frame looks cool too.

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PostPosted: Sat May 08, 2010 7:02 pm 
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mick5166 wrote:
Nice one fella glad it worked for you.I did this conversion using a 2006 z1000 transmission in my C2 and the gearchange is spot on. My zx9 gear box was crunchy and on inspection the gear dogs showed a lot of wear on 3RD & 5TH on input shaft.The z1000 is a 953cc using zx9r crankcase and has same gear ratios. The transmission should work 2003-2006 z1000 !
Hey, it was your post that gave me the idea so thank you.


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PostPosted: Sat May 08, 2010 7:08 pm 
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Location: devon, newton abbot
i wonder if the barrel & pistons fit, must be a few about it there are gearboxs about, very nice how to =D>


Last edited by rjk1188 on Sat May 08, 2010 8:16 pm, edited 1 time in total.

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PostPosted: Sat May 08, 2010 8:02 pm 
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rjk1188 wrote:
i wonder if the barrel & pistons fit, must be a few about it there a gearboxs , very nice how to =D>
I dont know about the top end but the transmission fit real well.


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PostPosted: Sat May 08, 2010 9:05 pm 
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Location: sutton in ashfield, snotts. E1
I thought the Z1000 engine was a bored out ZX9 engine anyway.


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PostPosted: Sat May 08, 2010 10:05 pm 
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good write up =D> =D> 8)

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PostPosted: Sat May 08, 2010 10:37 pm 
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Bore and head are styled to look like an air cooled lump though.

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PostPosted: Mon May 10, 2010 1:04 am 
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nice one! i'll be doing this soon in the winter 8)


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PostPosted: Mon May 10, 2010 1:06 am 
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well done =D> =D> =D>

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PostPosted: Mon May 10, 2010 4:39 pm 
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brilliant write up & good pics but still probably beyond me.


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PostPosted: Mon May 10, 2010 5:27 pm 
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Rob wrote:
brilliant write up & good pics but still probably beyond me.
Well believe me, I am no mechanic but with that Haynes manual it was not that tough.


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PostPosted: Mon May 10, 2010 9:07 pm 
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fran9r wrote:
Bore and head are styled to look like an air cooled lump though.


That would be a better look on a fighter. Very interesting. :!:


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