crashtech
Zone Head
Posts: 574
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posted September 11, 2011 12:19 PM
WTB ZX12R motor complete/ loud noise in mine
Hi guys....I have a major rattle in my motor. No Knocking just a "tinging" rattle from the bottom end rear of motor. Rog Twito has pulled the clutch out and swapped baskets after inspecting and no fix or change. Mike C. has the bike now and has pulled the clutch out again, nothing. Pulled oil pan and looked around at oil pick-up, trans gears, pulled shift forks and shaft, checked rods, nothing. No debris in pan and clean oil. Checked starter gears and nothing. Checked balancer and nothing. Pulled timing cover and chain looks good and clean with no debris in bottom of galley. The compression is great on all cylinders and starts right up and runs great and shifts through all gears up and down with NO change in noise. The noise is RPM related however. Rev it and it gets goes from a loud click tick at idle to a fast grinding like dragging a chain/gear across a jagged piece of metal as the rev's go up.
I am curious to find a complete motor with low miles to swap in and tear mine down complete. I dont care if it is a big bore or not just need it running good and quiet. I have the complete billet clutch and reliability goodies to go in it (timing advancer, mech chain tensioner, FP shift kit)
If no motors then please give us some suggestions on your experience.....
Thanks
  
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krexken
Zone Head
Posts: 732
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posted September 11, 2011 04:25 PM
My guess is bad bearing on input trans shaft. Hard to imagine one going bad but who knows. Be interested to know what you find out.
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zx12mark
Pro
Posts: 1654
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posted September 11, 2011 06:58 PM
yep ,you got a case splitting party in your future.take your time..............
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crashtech
Zone Head
Posts: 574
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posted September 11, 2011 07:05 PM
The trans input shaft turns free and smooth with the clutch assembly out. The noise does not change from N or in gear while running nor with the clutch engaged or not.....
Im not afraid of splitting the cases.....just a bunch of work and would like to keep it simple if possible..LOL
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crashtech
Zone Head
Posts: 574
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posted September 12, 2011 07:14 AM
motor is coming out this weekend............Stay tuned....
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krexken
Zone Head
Posts: 732
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posted September 12, 2011 06:59 PM
Starter clutch thingy?
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crashtech
Zone Head
Posts: 574
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posted September 12, 2011 07:24 PM
Well I dont know.....Its coming out in the next 2 weekends and we are going in....Going to get the trans cut while in there.......Oil pump gears were scraped when removed today and inspected. ....Crank gear had some teeth scraped a bit while in oil pan but not bad. Something went through just got to find it. Its in bottom somewhere..Hopefully filter got it after pump....Stay tuned....
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crashtech
Zone Head
Posts: 574
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posted September 19, 2011 07:34 AM
Well got the motor out and cases split today. The damage started from a false "N" on hwy 85 while downshifting to pass a car. That damaged a gear in the trans. That metal from the gear went through the gears of the crank that the starter clutch and counter balancer spin on. The horrid noise that was heard while the engine is running that has been so hard to diagnose is coming from the starter clutch. It is in the center of the motor so when it rattles it resonated through the whole lower cases. The manual states that it should spin free (it does not) and if it makes noise to replace (it does a LOT)..I will be replacing the damaged gear in the trans and having the whole thing back cut. Replacing the starter clutch brand new. Replacing the oil pump that the metal scarred. Mike already cleaned up the crank gear and ordered the oil pump....
Hopefully it wont be long...Maybe a few more weeks......
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tuusinii
Pro
Posts: 1031
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posted September 19, 2011 09:47 PM
Make sure that the gear axles are straight after You broke Your gear. On my fathers Z1300 it wasn't noticed the first time around and so the transmission broke again soon after...
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crashtech
Zone Head
Posts: 574
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posted September 20, 2011 03:46 AM
Thanks...No broken gears this time. Just nicked up the dogs on 3 and 4 this time. The whole assembly is at the machinist now getting the works (up and back cutting, magnafluxing, balancing, ect.).......If the axles are damaged they will find it....
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psycho1122
Pro
Posts: 1608
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posted September 25, 2011 06:00 AM
 Edited By: psycho1122 on 25 Sep 2011 14:02
False Neutral(s) and back cutting will make the gears weaker. Look into billet gears here...
http://www.robinsonindustriesinc.com/
Stock gears are windowed and WIIL crack sooner or later. At he very least, have all of them magnafluxed.
____________
You say PSYCHO like it's a BAD thing!!
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crashtech
Zone Head
Posts: 574
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posted September 25, 2011 12:22 PM
Edited By: crashtech on 25 Sep 2011 20:23
Thanks Phsyco.....Man I loved your bike. You still have it?.....Yes everything got magnafluxed after cutting before assembling trans. I only cut them to help ensure this wont happen again. Going to tour ride now and granny shift, tired of breaking shit! I believe this will be my last Kawi however, possibly motorcycle. I am sooooo sick of being ready to re-assembly only to find out 1 part that is needed is on back order......starter clutch this time (dont know how long, yet).....3rd and 4th gear on ZX11 last time (took 7 weeks).....pricks!! Riding will be over then for the year.....Dont understand it my last 01 12R was indestructible....NEVER a mech failure in 4 years of beating the shit out of it...Hell HDL owns it now and has turned over 45k or 50k miles and no problems. Scooters dads prestine 00 is turning out to be a major mech POS.....
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