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ZZR1200 - Splitting the Case..

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  • ZZR1200 - Splitting the Case..

    Im trying to split the case of my 2003 ZZR1200 without much joy and not being 100% convinced i have everything undone holding the two parts together, can anyone suggest if i need to
    take the gear linkage mech off attached to the side of the case? The manual suggests that i do but can't see how that's holding it together.

    The bikes has developed quite a knock when you turn the sprocket spline which seems to be coming from somewhere inside the gearbox hence the project. Any suggestions would be really appeciated.


  • #2
    Hard to tell if you are missing anything from those pictures. I notice there appears to be a battery cable still attached. Did you remove the top side case bolts?


    • #3
      Thanks for that, the final bolt was attached to the ground strap. Once i removed that, i was able to pry the case apart and came apart fairly easily..

      Having finally got round to splitting the case today, I'm still trying to find that illusive knock. i think I've pinpointed it to the clutch basket area which had a real wobble when i spun it. There seems to be high temperature discoloration at the end of the spline at the clutch end (is this normal?) and markings on the clutch basket which I'm sure is not normal(photo). I guess a new clutch basket and needle bearing is on the shopping list however much they are, but its just that knock which I'm stumped to know what that could be..

      Attached Files


      • #4
        What knock??? Was this bike crashed?

        You'll need a Tensioner Tamer or the pressure plate will get beaten up again.


        • #5
          When you spin the clutch spline round with your hand you can definitely feel a ridge or it catching every rotation or so but the larger shaft bearings seem to run smooth. I'll probably need to have a real good look at the needle bearings perhaps to see if there is any pitting or something caught in them as there is a fair bit of metal caught in the oil strainer in the sump.

          As you can tell, i'm not the most knowledgeable on this and was considering taking it to a specialist for them to fix although if i can do it myself and learn something then all the better.. .

          Ok, Added Tensioner tamer to the shopping list.

          I'm just wondering when would you scrap a clutch basket or would replacement needle bearings be all that's required and that scorching to end of the clutch spline is that normal?..


          • #6
            Fascinating to watch over your progress. There are some very knowledgeable blokes occasionally on the site so hopefully you get some good advise. Good on you to take it apart and show.


            • #7
              If the fingers have deep grooves from the plates, Kawasaki recommends replacement. That baskets doesn't look to bad. Pull it, and inject everything recommended by the manual, and I bet you'll find your problem.

              Putting it back together is the tricky part.


              • #8
                I agree with avtech2 that the basket fingers look fine. That splined shaft you're spinning is the input shaft to the transmission. The 'ridge' you feel may be something wrong on the transmission end, and not the clutch bearing. Maybe a bad bushing on one of the gears, but that is just a guess.
                How To Cheat on Personality Tests
                1. When asked for word associations or comments about the world, give the most conventional, run-of-the-mill, pedestrian answer possible.

                2. To settle on the most beneficial answer to any question, repeat to yourself:
                (a) I loved my father and my mother, but my father a little bit more.
                (b) I like things pretty well the way they are.
                (c) I never worry much about anything.
                (d) I don't care for books or music much.
                (e) I love my wife and children.
                (f) I don't let them get in the way of company work.
                From <cite>The Organization Man</cite> by William Hollingsworth Whyte, 1956


                • #9
                  Finally got to the bottom of whats going on with this. There's a chipped tooth on the input part of second gear causing it to partly ride over its partner on the driven end resulting in the whole input shaft moving up and down.

                  So.. what im going to do is replace that input cog (driven end appears fine) and replace the nearby needle bearing and then button it back up. As with the outer clutch basket, i was confused about the scratching on the outer basket having never seen this before and confused how it was not in the direction of spin with no marks on the casing as i thought it could be rubbing but got told this is from manufacture being grind marks of excess metal from when they mate the two casts together. cool,now making some progress..