Splitting the lower cases - 1990 Kawasaki ZZR1100
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- Опубліковано 4 лип 2022
- The dogs on the input shaft of the 1990 Kawasaki ZZR1100 definitely look knackered which is why I'm having a 5th gear problem. But to replace them I have to split the lower crank cases.... So that's what I'm doing...
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Love your work.
Gears work like this; small driving large is a low ratio, smallest driving biggest is 1st gear.
Large driving small is a high ratio, largest driving smallest is 6th gear.
You can measure diameter or count teeth (safest to count teeth) to work out which pair is which gear ratio.
Thank you matey, that's a good way of remembering it which I'm pretty sure will stick. Why didn't I thinknof it that way !?! 🤔😁👍
Awesome! 👍❤ First proper strip-down I did was for a BSA Bantam unit - cases wouldn't separate 'cause I had literally overlooked 2 screws hidden by thick dirt - I did the cardinal sin and had screwdrivers hammered into the joint at various places to force it apart - release the pressure, it slammed shut like a clam - to it's eternal credit tho, it didn't break .. 😁
I'm willing to bet more people have done that than will ever admit to it matey. They built stuff tough back in the day as well... 😁
Anyone else holding there breath when the bottom came off 😁...
Your doing a great job,, it's alright for us lot just watching ..
I reckon with the top rebuild you have just about had this engine completely apart 👍
I know I was matey 🤣😂
Thinking about it, it's on rhe crank rather hasn't been out rhe bike now 🤣😂😅
It is like watching Deja Vue . Late '80's I purchased a z1300 for a trip to Spain , that was in Boxes [ just the top and Sump off the Engine ] just like you , I then had gear problems , just like You , so I took the Engine out , and split it , just like You . But , when the gearsets arrived I had ordered , straight away I noticed that the Gear Selectors had been modified , and were a lot beefier , so just fitted them . If I had known , I could have replaced them with the Engine in situ , with just the Sump off . I mentioned in an earlier Episode that '' I know how you feel '' . Nice work Quicky .
Hehehe... beware of bikes in boxes. 🤣😂
I'm busting my tail at the minute trying to get it all done before my holiday, but there's quite a bit involved in it and it's so much easier with the engine on the bench. I can't imagine doing this in situ... 😁
@@QuickBikes . 'Morning Quicky . Do not burn out before Your Holiday , it will still be there when You return refreshed .
I would matey, but I really really need to be mobile again ASAP. To be fair I'm not sure I'll be riding it again before holiday, but it should be sorted 😁👍
Good job mate. My race bike jumped out of 3rd with a 1/4 of that wear. That ones well knackered. You'll be back on the road in no time.
They're not very good are they 🤣😂 Totally battered on the input shaft but the output shaft doesn't look nearly as bad 🤔
loving it mate, worst part is over now! :)
Yeah, but today had its moments 🤣😂😅
Hunky dorie, great video, hope you can give shout outs at some point Andy Richardson, thanks, great watching dude
Evnin' Mr Quickly, see, I said it wouldn't be so hard. Tip to the wise, when splitting cases refer to the exploded parts diagram, it usually shows all the bolts and their location, then count the bolts you've removed.
I've got that sitting on the side for Fowlers 🤣
As much info as I can get the betterer in my book 😁
Great advice PRB Even the main workshop manuals don't always show all the bolts
@@garyyorke1080 Parts diagrams are often good reference, especially for assemblies you haven't taken apart (or forgotten how they go back together again) 🙄🙄
I could do with one of them for which sump bikes goes where now 🤣😂😅
You certainly improving your mechanical knowledge,skill and confidence with this bike👍. Loving it.
It's the best way to learn I find, just have a go 😁
Remember to align the tiny punch mark on the balancer mass with the center of the oil passage hole on the lower case when meshing the balancer gear with the crankshaft gear during reassembly of the cases Simon...
BG.
Yup, did that today and was wondering how you get it in the right place.... Simple really, I thought it was going to be some convoluted exercise 🤣😂
Great work mate. You're doing the right thing. Hope the *new* components resolve that 5th issue without introducing additional woes!!!
Thank you matey. The new gearbox looks really good and I'm sure will be an improvement. Cheers 👍
Delivery done a video on plastic welding very informative and histericaly funy .just putting it out there !
Delivery... is that the channel name matey?
@@QuickBikes bloody predictive text was supposed to the del
Hehehe... I thought it might have been matey 🤣😂
I normally blame predictive text, buts it's really just my chubby thumbs 👍
nice one
Thank you matey 👍
It could be Worse. Could be diving into the 79- 81 KZ 1300 six. See Alan Mallard's took 2 1300 made v 12 in his backyard shed.
I've heard about him but never watched him... 🤔
@@QuickBikes He's from your side of the pond. Watch and learn from the master. I'm serious.
Oh Boy you've stepped into it now..LOL...That definitely is your problem area ...You'll save a fortune using parts from the "new" gearbox!..The individual parts from the dealer (if they are available) will be soooo pricy!..Looks like your on the right path..Good Luck and it should be back "up" soon...👍🗽🇺🇸
The new gearbox looks really good as you'll see in the next video. VERY pleased with it 😁👍
Ace 🙂 👍
Thank you matey 👍
Nice work.. Looks like the dogs are pretty worn.
Hope the second hand gearbox is ok.
The new one is dead spanky by comparison with hardly any wear at all compared to this one 😁👍
I've seen dogs like that before, clutchless gear changes will do it, normally only this bad when people do down shifts without the clutch, doing great so far bud more than some would take on 👍👍
See, I thought it was because of clutchless shifting.... its weird how its mostly just on the input shaft though, I thought it would have been both shafts... 🤔
I think it's caused by the force of the engine slamming into the dogs when the clutch isn't used to softly engage them 👍
I think you're right matey 👍
bewdy mate, good progress, 1 of dogs looks especially bad so hopefully that was it, will see, tomoz! o ring on the starter looked a bit dodgy too :) look on the bright side, more shit to clean before re assy :)
Hehehe... its going alright so far dude. I'll be cleaning everything as I put it back together, but I've noticed a few wear marks here and there which I'll keep an eye on next time I'm in here 😁
Awesome !! those dogs are realy mangled ,wont engage propperly so fifth will not engage or scape loose , now thats the damage that caused the simptom , now whats interesting now i guess its the real issue why the dogs worn out ?... worn forks? poor profile in the cam of the selector drum? loose factory tolerances? this bikes are quite infamous for that kind of troubles ,youre doin great with it , best wishes with the replacement gears!! cheers!!
The newer gearbox is brilliant by comparison and I'm convinced this is going to fix it. It could be lots of clutch less shifts and banging your way through the box that's caused it. There's no way of knowing really I guess... I can totally understand why 5th failed though looking at it 😁
Hehe .."Battered" absolutely muntered mate lol . Just a thought be aware if the main crank bearings are exposed when ya turn the bottom case over . And yep I got a plastic weld cheapo shite gun but my box didn't break lol. Trick is heat up push in and twist it a little release trigger and wait 10 seconds or so for it to cool down or your gonna pull the bloody bit back out like I did lol. ...
It's a coming matey .. bit of a baptism by fire on splitting those cases .. I remember a mate saying he removed all the bolts and whacked the shit out of the cases on an rgv 125. Forgot the bugger under the carb mount ( hidden behind a bearing clamp ) and yup crack!!!! . Ali welded laters ...just be careful light taps if it don't feel right don't force it ..
I'm lovingbhaving a go at this matey and although a mechanic would have it done it a few hours I'm sure, it cool figuring out what everything does. If I had to don't again, I'm sure I'd be a bit quicker and more confident, but not much 🤣😂
@@QuickBikes your having fun doing it and learning along the way . What better way to understand the engine .. and yep the next one you do ( hopefully not this again ) should be easier as you'll have a lit more confidence in how to 👍🏻👍🏻
ASBO is getting a complete rebuild, but I'm much more confident to have a go at it now 😁
I'm just wondering when you take off the clutch drum, I mean before it falls on the floor by itself, by now, there is basicly nothing holding it, and as another guy in the comments mentioned, check Allen Millyard, right now he is building an old Kawasaki 3 cylinder into a 4 cylinder
As long as the drum Centre is in place, it can't get past the cases, but get that out of the way andnit has a mind of its own. I really though it would be fixed in place a bit more securely 🤔
Hope my gear box doesn’t go soon. That’s a big job. Well 4 me it would be. Nice one quickly
There's lots of bits involved and it does take up a fair amount of space, but its actually not horrendous.... it just seems like it 🤣😂
Those cheap plastic repair kits wirh the staples are terrible the repairs last about ten seconds its b etter to get some of the same material and melt it back togerther using a soldering iron if you do it right its almost as good as new ..almost , should be reliable after you finish this like I said on FB cant wait to see it run again
I thought I'd give it a go as Jack next door had some good results with it... I've still got the ABS resin kit sonitll be getting that as well. 😁👍
Dogs and selector forks need replacing at least is my thoughts but you’ll know what you’re looking at.
It's quite surprising the quarter you see once you pull the whole assembly out and go poking around... very surprising 😳
The udders cracked me up. Was the factory loctite the white stuff, or the harley-specced brown?
Hehe... the white stuff apparently 😁👍🤣
Where did you get the c model online workshop manual? I have only found a d model manual online.
It was very kindly sent to me matey 👍
Just ditch the fairytales and stick to the workshop manual.. after all you did have to remove the starter and the dynamo like it said..
Dismantling is coming along a treat, hope the "reverse procedure" will be equally satisfying :-)
I've had quite a good day today matey as you'll see shortly 😁🤘
1st job, use the kit in the box to fix the box 😁
🤣😂😅 I hadn't thought of that... Brilliant 😁👍
Wish I would have kept my oil topped off and didnt blow the 3rd piston. /:
I have to do the same thing on my bike....🤦♂
What's that? Change absolutely everything 😁
Tis a labour of love matey 👍
well at least you can weld the handle back on the box
I binned it.... 🤣😂😅
In be for ...'now where did I put that plastic welding gun?'
Hehehe... 🤣😂
You’d almost think the people that build and assemble these bikes are just downright awkward and don’t want us tampering with them 🤔🤔🤔🤔🤔
Hehehe.... I know really estate on a bike is at a premium, but they squirrel some of these bolts away in some dead sneaky places don't they 🤣😂
You just chucked you money in the bin plastic weld gun ?
ABS plastic hot staple gun. Apparently they're pretty good at repairing broken fairings, but the case ain't so great 🤣😂
@@QuickBikes mite try a ordinary soldering tool could of save you but hay review it could be fun. Lol
Must admit guys I always repaired with a soldering iron but needed to repair something without burning both sides and wanted a bit more strength. I was pleasantly surprised how good the cheapo thing was ..
Hunky dorie, great video, hope you can give shout outs at some point Andy Richardson, thanks, great watching dude
Thanks for watching matey 👍
@@QuickBikesbikes have been in the family for 50 years when my dad had a Honda 750 with side car for 3 sprogs. Great times, also a great channel happy watching
Thank you very much matey, very kind of you 😁