aliveagain
Needs a life
Posts: 5033
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posted August 23, 2007 05:51 PM
ball bearings in 5th gear
I disassembled my transmission to clean out any metal particles that might have gotten in when I lost the rod bearing.I used a dab of grease to hold them in place but just saw in the book not to use grease as it goofs up the positive nuetral finder.Any tips on putting them in place and installing the gear?
I think I found out why the tranny wouldn't go together as there is one double gear that is slightly smaller on one side.I bet I put it in backwards and that is why the bearings won't sit flush in the casing.I'll have to bring it to work tomorrow and reassemble it the other way.
The book says to replace the clips everytime they come off.Anyone ever have any experience with this?
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I wondered why the baseball kept getting bigger. Then it hit me.
  
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buddy
Expert Class
Posts: 335
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posted August 23, 2007 07:19 PM
If you're talking about the little circlips like on the oil drive gear, mine wasn't replaced and it came off after about 5 minutes. The oil drive gear came out, got caught up in the clutch basket and pulled side ways and broke a chunk out of the case as well as damaged the basket. Replace the little devils.
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MadMike
Moderator
FEAR THE BLACK FLAG!!!!!!!!
Posts: 6579
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posted August 23, 2007 09:48 PM
and his is the second one that did that!!!! that I know of, DWB had almost the same thing happen... he got his shut off before it damaged the case though...
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entropy
Moderator
Posts: 8671
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posted August 24, 2007 02:25 AM
Definitely replace the clip on the oil/water pump drive shaft if you pull it off.
the clips which hold the gears in place... hmmmm...
If the manual says replace em, prob a good idea to do it. I didn't replace em the last time i had my trans apart, but, prob should have.
the 3 lil balls for the neutral finder?
you can assemble the outout shaft gears etc vertically, or just throw those lil balls away. I don't run em and many other folks don't either.
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aliveagain
Needs a life
Posts: 5033
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posted August 24, 2007 03:49 AM
If I don't install those ball bearings for the nuetral finder,will it pop into second at a standstill?
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I wondered why the baseball kept getting bigger. Then it hit me.
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entropy
Moderator
Posts: 8671
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posted August 24, 2007 04:18 AM
it'll go directly into 2nd from neutral without the balls.
a titsch harder to find neutral but no big deal
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted August 24, 2007 06:08 AM
I like 'em (street rider 'ya know...). Like entropy says, do the stack vertically.
Funny story-
Chicago 1974, I have my '73 Z-1 finished with the complete Yoshimura kit ( one from the cover of Cycle World cover bike that year- Remember that? of course not....) Close ratio trans, cams, head, carbs....etc. Anyway, the bike is in my family room (no, no wife- then OR now) and it's FINISHED! So I sit on it and rockin' it back and forth to try to shift it through the gears.
NO SECOND GEAR! WTF? Am I pissed so it's out with the engine, bottom case off - trans out.... and of course then remember those three little balls. I 'll never forget those three little balls. But I do like the feature. It's just so Kawasaki.
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ninja12
Needs a job
Posts: 3310
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posted August 24, 2007 06:21 AM
Doug,
I know it's mean, but I like to hear about others who jump and to waaaaaay too much work
over a little problem. In my early days I replaced a engine, then found out the original
engine had a bent push rod. oops.
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TRNorBRN6001
Needs a job
Posts: 2021
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posted August 24, 2007 07:51 AM
Yep, replace those cir-clips and be careful not to accidently mix those gears up.
Robinson does a nice cut and polish job, and he has a nice low first gear. I think
Mr. Hill might have a set of overdrive 5th and 6th gear left as well.
I have seen an oil pump gear back out and grind a little on the basket,
kind of scary!
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aliveagain
Needs a life
Posts: 5033
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posted August 24, 2007 08:49 AM
Dealer actually stocked the clips and gave me the same price as Ron Ayers.  Reversed gear on the input shaft and cleaned and reassembled the gear with the 3 balls.I love my job to be able to this on the side.
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I wondered why the baseball kept getting bigger. Then it hit me.
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nox
Needs a job
PMRA / TMRC Super Street 4022
Posts: 3745
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posted August 26, 2007 11:14 AM
I had same issue, with the shift kit on my zx6r........
Finally factory called me back, and said, OH you have a Kawi........
I can put mine in 2nd sitting still...........
Rnd Trans and cut drum though.........
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