If it is slipping from the gear it is in then it is probably the because the Shift Fork is bent, and you have to take the bike apart top to bottom. ZZR's are known for it. In order to reach the shift fork you must tear down the whole bike. Good luck with the work.
I now this is a bit late to reply to this one, but...
I had the same problem, slipping from the 2nd gear. on 1994 ZZR 1100.
I had to take the bike ALL THE WAY apart, to reach the gears. Painfull..
The forks were ok, not much bending. Ear thickness was within the range.
There was some "wear" on gear dogs, and on opposite gear there was wear/chipping marks.
So, i've bend the fork to normal, and thought this will solve the problem. But did not... looking to replace full gear set /drum/forks.
Can anyone suggets store/site where i can order some? There is no Kawasaki dealer in my coutnry.
Appreciate ahear.
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Check your de-tenton spring and roller on the shift drum "star" behind the clutch basket. The worst case is that you shift forks could be bent or the under cut gears in your trany may be worn.
Let me know if you need help getting to backside of the clutch basket.
Mark
C.C. Motorsports
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