1993 Zephyr 1100 2nd gear S.O.S. blues

[probablecause]

Ok, on hard acceleration, my 93 ZR1100 pops out of 2nd gear and back into neutral. I love the bike, 25k miles and a 9.5 out of 10 cosmetically. This has been my dream bike since selling my 83 GS1100, so I want to keep it and bite the repair bullet. Just need some parts and cost info based on the below:
1) Replace the gears and whatever parts go with that (complete gear set, etc)?
2) Same as number 1 but whatever other parts you would go ahead and replace "since you have it cracked open"?
3) Find a donor transmission that does not have that problem (which other Kawi transmissions work)?
4) To hell with it and find a new donor motor (which years can I just swap in)?
Final question is does anyone know what year how many miles would trigger this?

[Sabbath-66]

Try fitting a pro shift kit, may help. Good luck

[Richard]

To point 4, I have 55000 kilometers on my dial and haven't had any gear issue this far on my 750 (knock on wood )

[Richard]

Did a search on kawasaki zephyr factory pro kit and found this video from Swampy (also on this forum)
In the footnote he mentions this is not a repair kit, more like a prevention kit...

[youtube]https://www.youtube.com/watch?v=6pk8xRT8U1c[/youtube]

[vambo]

If your bike jumps out of 2.gear it´s too late for the Factory Pro kit
My guess is that you have to split the engine and change the gears....

Leif

[probablecause]

Does everything come out of the engine from Cam, Pistons, etc.?

[vambo]

Yup,you have to split the engine block..

Leif

[probablecause]

Now the big question is where can I get the parts online. Partzilla and other well known places say that they are currently out of stock.

[750R]

as i Know you don't need to empty the Cranckcase - Cams an Cranckshaft can last in the Engine if you open it from the down side.

You need to open the Oil pan, get the Oil Pump and the Oil-Pump plate out and then you can open the Cranckcase. Then you need to get out the Transmission and you need to Chance the GearWheel of 2/5th Gear (i think these were the ones...) and the Shift fork.
Most time the "Claws" of the Gear Wheel are worn so the Wheels push away from each other - so there is a force on the shift fork . then this Thing is getting worn out nd the Wheels can jump from Gear to neutral.
Not shifting trough complete ( Factory Pro is helping to do this ) increases the erosion of the Clawas on the Gear wheel.

I hope it'S half way understandable. if not i need to take some Photos of my crashed gearbox

Greetings

[750R]

and to the Part numbers:

Problem is that they cant be found because Kawasaki tried to fix the Problem with other Parts and the took the old number out of the Program but the didn't set the new one in....
if anyone knows the Numbers it would be nice to post it for all to save the knowledge ;9