Droid
Expert Class
Posts: 133
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posted April 09, 2006 10:13 AM
Hi Guys New to forum and have a problem already!!
Hi All,
I'm new here so i hope you guys don't mind letting up a bit of advice on my first post!
After a bit of combined last minute braking and a couple of downshifts my box seemed to miss a gear and a horrendous crunch came from what sounded like the clutch side of the engine, i coasted to the side of the road clutch in and can engage first gear and neutral but didn't like the occasional nasty sound coming from within in neutral.
Got recovered, dropped the oil no obvious debris had a quick look inside the clutch cover nothing missing, but cannot select any gear above the neutral detent.
Any ideas i've only owned the bike a fortnight BTW 2001 ZX1200A1 or 2 dunno??!!
Thanks in advance
Droid
  
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MadMike
Moderator
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posted April 09, 2006 10:21 AM
so if I understand correctly, while the bike is moving you can not shift up into second gear?
if that is correct you have broken your tranny... probably...
first thing to check is your shif forks and make sure you did not break one of those.. and you dont have to split the cases to remove them!
MM
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Droid
Expert Class
Posts: 133
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posted April 09, 2006 10:26 AM
MM
Thats correct, 1st will engage and i have clutch control and i can select neutral but the gear lever feels as though it is doing nothing when i go for second, are the shift forks accessable from under the motor??
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wylde
Expert Class
Posts: 371
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posted April 09, 2006 12:36 PM
QUESTION?? by any chance have you taken the shift linkage off,,(where it attaches to the shift shaft) because if you put it on upside down,,it would act very screwed up,, requiring you to shift 1 up and 5 down instead of 1 down and 5 up..
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There you go again,,NOT being aware of yourself !
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Droid
Expert Class
Posts: 133
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posted April 09, 2006 02:28 PM
No i was riding it when this happened.
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wylde
Expert Class
Posts: 371
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posted April 09, 2006 02:47 PM
Gonna have to yank the basket to see if there is any fork damage,,which can be done after removing the pan,,pain in the ass,, but better than having to split the cases,, there are a lot of guys here that can steer you alot better than i,, so just hang tough till you get some good responses and feedback as to your particular problem.
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There you go again,,NOT being aware of yourself !
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MadMike
Moderator
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posted April 09, 2006 04:12 PM
yep, pull the pan, and you will be able to see up in there. and that will tell you if you have any broken gears... you will probably have very large chunks of gear in your oilpan if you blew out second...
do you have a manual???
you will need one it makes it easier...
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speedgene
Zone Head
Posts: 996
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posted April 10, 2006 09:41 AM
 Edited By: speedgene on 10 Apr 2006 10:47
Like MM said, pull the pan and look for a spring or parts there of? 92081 is the link between shifting and not. That spring makes contact with the shift drum. If this is not engaged, then all you can feel is the 92145 spring returning the shift lever back to center.
No doubt something like a fork took on a little excessive wear.
http://kawasaki.com/scripts/ImgServ.exe/convert?ilFN=e:\epcimages\I10\I1024\E1370.TIF&ilIF=P&ilSC=25&ilIV=0&ilBR=0
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E-tard
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Droid
Expert Class
Posts: 133
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posted April 10, 2006 11:31 AM
All sorted guys looks like 2nd gear blew out. Started pulling the lump out fortunately 3/4 of the gear is still on the shaft and damage looks limited to 2 gears only!!!
And i seem to remember that kwakkers were meant to be bullet proof!
Any one got a blown engine that they wanna sell for spares!
Droid
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12r1
Expert Class
Posts: 390
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posted April 10, 2006 03:42 PM
They are basically "bullet-proof", but anything can be broken by bad shifts, very unusual abuse, or even if some dumbass impacted the front sprocket off with it in gear...
jeff
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blitzkrieg
Needs a job
Road kill = Free lunch.
Posts: 2044
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posted April 10, 2006 05:14 PM
You don't break a 12 tranny by last minute downshifting. 
Tell us the truth and save yourself.
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jhinderliter
Zone Head
Hacksaw
Posts: 541
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posted April 10, 2006 06:42 PM
oh geeez here we go again!!!
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My other ride is big and green too!!
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blitzkrieg
Needs a job
Road kill = Free lunch.
Posts: 2044
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posted April 10, 2006 07:43 PM
quote:
oh geeez here we go again!!!
I never jumped your shit bro. Go back and read the posts.
I DO know you aren't going to rip the tranny out of a 12 by missing a shift, though. 
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"BTW....You need to get a girlfriend who's last name isn't .jpg"
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junior s
Pro
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Posts: 1644
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posted April 11, 2006 05:15 AM
Shift hit false neutral keeping it pinned on the limiter and kicking the shift lever might just do it ... maybe ?
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Get up off your ass and ride !!
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Droid
Expert Class
Posts: 133
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posted April 11, 2006 05:34 AM
"You don't break a 12 tranny by last minute downshifting.
Tell us the truth and save yourself."
Bottom line is it did break and no i was not on the limiter, etc, etc, etc.
I'm staring at a damged 12r gearbox and crankcase so a little sympathy would be more appreciated than telling me how i did or did not break it!
With 28000 miles on the clock of which i can only vouch for 48 of them I don't suppose some w@n#3r in the past has probably abused it perhaps??
(A very p!55ed) Droid
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jhinderliter
Zone Head
Hacksaw
Posts: 541
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posted April 11, 2006 05:47 AM
just playin blitz
peace!
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five 0
Expert Class
Posts: 215
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posted April 14, 2006 12:32 PM
You can find some used trannys. I have a couple.
5-0
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Droid
Expert Class
Posts: 133
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posted April 14, 2006 12:36 PM
Ta for the offer have tracked one down should be with me after weekend,
just gotta repair the crankcase where the shift rod bent and forced the locating boss.
Anyone in the UK confident of their alu welding!!! Only £1200 for the new crankcases!!!
Droid
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MadMike
Moderator
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posted April 14, 2006 12:39 PM
Hey Droid your going to have to split the cases to replace this. I am just warning ya up front, you might have already known.... there is a trick to it if you do not want to disassemble the entire engine... but you have to be very careful!
MM
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Droid
Expert Class
Posts: 133
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posted April 14, 2006 01:10 PM
MM
Go on coz i have the bottom crankcase off and the tranny out so enlighten me if you can save me any grief!!
Droid
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MadMike
Moderator
FEAR THE BLACK FLAG!!!!!!!!
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posted April 14, 2006 05:33 PM
your cool if you are that far already just be careful with your bearings and the crank so you dont move or bump anything... a new tranny will go right in and you should be able to bolt everything back up....
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Droid
Expert Class
Posts: 133
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posted April 15, 2006 02:57 AM
I'm gonna rebearing now im this far in, as the two outer mains look as though they are taking more load than the other three. What about the main bearing bolts who is reusing or is it a big no no.
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Y2KZX12R
Needs a job
CompetitionCNC.com
Posts: 3762
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posted April 15, 2006 04:10 AM
Look at all the fork contact pads for wear. Measure the thickness. The 2nd gear fork will be a good indicator how often the previous owner powershifted the bike out of first gear.
The book doesnt say anything about replacing the case bolts (main bearing bolts).
It does say to replace the rod bolts and not to reuse. But you shouldnt have had to undo the rods anyway.
You might want to replace the tranny bearing closest to the sprocket.
Dont forget to time the counter balancer while you drop the case half back on.
If the oil clearance on the mains are ok I wouldnt bother replacing the bearings. Your gonna see some wear. Dont worry about it. Most bearings are needlessly replaced. And new ones will have tight spots and will need several hundred miles to breakin in because the case halves arnt 100% concentric, they never are. Same as the rods.
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