Fitting the new gearbox - 1990 Kawasaki ZZR1100
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- เผยแพร่เมื่อ 5 ก.ค. 2022
- The new to me gearbox is here and it's sooooo much betterer than the old one. If I can get this fitted and working, the 1990 Kawasaki ZZR1100 should be way better to ride.
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doing a great job, someone will benefit from this video in the future
I hope so... its nice to think it's helpful to somebody 😁
Thanks for the vids… keep it coming! I have a 1998, the third gear kept popping out. Local shops charge a small fortune for this and parts are difficult to find. I swapped my engine for a used one off ebay haven’t had a problem. I found a gearbox on ebay in good condition a few months back and your vids are helping me build the courage to do the job.
Awesome, but don't take everything I say as gospel matey as I'm learning this stuff. I wouldn't even start it unless you have a manual to guide you 😁
Best of luck matey 👍
Probs a slightly Bent gear change fork - diff to spot even on a full strip down without the OEM specs and a good surface table etc
No ya ain't boring mate I'm loving it I could sit and watch all day long 🎬🎬🎬
Thank you matey 😁
@@QuickBikes you are very welcome my son keep it up 😅😅😅👍
Not boring mate, inspiring 👍. Keep them coming.
Thank you matey, will do 😁👍
excellent stuff mate, didnt bore me at all - i love this sort of thing. every day is a school day etc, etc. cheers!
Thank you matey 👍
Top man, knew you could do it (without too much drama lol). This is what YT should be all about, people that have a clue putting difficult to find info out there for those that follow, kudos Quicky, nice work :)
Thank you matey. There really isn't much not there for ZZR's at all, so hopefully nits handy to see. Not a text book this is how to do it, but buys of it are handy to see 😁👍
yes, I know from personal experience that things can seem more complicated and daunting than in reality, especially in Hayne's manuals. And one imagines from the text that everything must be replaced
Hehehe... its very true actually, EVERYTHING 🤣😂
@@H-M-78 yip, it's (in my opinion) why the factory manual beats a Haynes everytime....but I think you also get used to them & start to understand them the more you use them, shame they're usually so pricey compared tho, but if you're planning on keeping a bike then I think the factory manual (& a factory parts catalogue/microfiche....which can also be a real help in seeing how things go together) are essential.
Agreed matey, very much so. Fowlers Parts is brilliant for exploded diagrams and part numbers as well. I use it all the time now 😁👍
WHAT A LEGEND
it was 9.22am when ya took the old shaft out , you are doing really well , we have ALL done that peg jumping out of casing thing only to be discovered AFTER the lower casing goes on ! ... and Im with u on that untorqued bolt . we know that feeling ,,,
Awwww... can you imagine striping it after all this work 😳
I know it could be helicopter, but even so 🤣😂
Finally getting caught up! Great to see you getting stuck in at it you will have it back on the go again in no time
Hopefully so matey, it's all going rather well I reckon 😁👍
Been watching with interest. Its always a bit nervy when you do something for the first time. I would have another look at that shaft that won't turn. I've not worked on one of these engines but it's basically the same as all other UJMs. Both shafts should turn freely as the clutch basket is not locked to the shaft. It only becomes so when the inner drum and the plates are installed. I may be wrong an I'm sure there are Kawasaki guys that could tell you but I'd check that again. Good luck.
There's been a few that mentioned this and I thinknit slipped into gear at that point. The engine is back in the frame now, but with the chain and gear shift in place I can select gears including neutral 😁👍
It all seems to going well, really enjoying the videos.
Thank you Ian 😊 👍
So far so good; fingers crossed for the next episode Q.
Thank you matey 👍
Great job!!! Cant believe how quick you got into this!!!
Sort of had to really as I don't have any transport at the minute 🤣😂
No not bored yet enjoying the videos 👍
Thank you matey 👍
Cracking result finding that gearbox Quicky, I reckon the "C" will be fine now it's with someone who knows how to use the clutch.
There really isn't any wear non it to speak of at all 😁
Exellent going chap! 😎
Thank you matey 😁👍
Well done 👍🏻
Thank you matey 👍
great stuff, keep on going.
Cheers matey 👍
Nice one mate, it's a bit ov a job going on 👍👍🙌
Yes it is matey 🤣😂
Good work Simon,, soon be back on the road
Hopefully matey, hopefully 🙏
Great video, always niggles lining everything up, but you managed, I would be totally lost doing all that, I know what it's like walking to work, and it's 4 miles a day, which is not alot, but that early in the morning, using scoot for work, its only a 50, but that gives me extra 45 mins in bed, then bigger scoot is for weekends, and NC500 in August. Look forward to seeing your next vid
Geddon, thanks matey, much appreciated 👍
You can do mine next lol just got my 05 honda cbf600s so glad to be back on the road again.anyway looks like ya getting there with it 👍👍👍
Hehehe.... what and deprive you of all this fun, and late nights, in stinking hot weather... I think not matey 🤣😂😅
Great vid, loving following this project! Only thing I did think though is where you said it would be handy to have a pic of shafts to show when it's in neutral, you didn't then take one to show on screen lol?!?! 🤷♂️
Hehehe... very true, I didn't... 🤣😂😅
Awesome !!
Thank you dude 😁
Love your channel and your way of approaching thing .when you say office do you have a dealership or garage
Cheers that gearbox looks realy scary
Thank you very much for watching matey, it's much appreciated 😁👍
As far as office goes, I have this place which I run my own business from and a fabrication job which keeps me very busy in a factory
No jokes on this one, proper score on a clean gearbox. It all looks a lot better than the old one, and definitely a good idea to put the entire unit in in one piece rather than mixing and matching. Did you mic the old selectors to see how worn they were?
You'll be back on the road in no time. I'm about to split the VF's carbs again...
Simon
I must admit that I didn't matey, I was just more concerned that the replacement was in spec 😁
You should be able to rotate the input shaft and check you have gears..
Also did you put sealant around the bolt holes in the cases or oil might leak from the bolt holes.
Good work! It probably just snapped into gears again, try to shift it to neutral!😁
I've just been down the shop, put the chain and gear shift back on it and I can spin the wheel and select gears, so I'm hoping we're all good. It's a bit stiff mind, but I'm still poking around... 😁
New geaebox!! Lucky bastard
New to me matey 🤣😂
U should b able to turn that centre shaft in the middle of the clutch it got no clutch plates or pressure plate or springs I goes directly thru to the gearbox with out turning the crank! Yur getting their mate
I've actually got the engine in the frame again now, but can spin the back wheel and select gears, so Im hoping it will be OK and was just in gear when I tried on camera
Fabuloso ... but can't understand how input shaft could locked to the crank if there are no clutch plates in it ... 🤔
Watch the next video matey 👍
Very concerned about that shaft not turning only the outer clutch should be meshed with the crank, also you didnt need to put the clutch on until after the cases were sealed, did you lube the crank shells?
Yeah, me too matey, although the engine is back in the frame with a chain and gearshifter fitted and I can select gears including neutral. I may have something wrong, but won't know till I test it out. I think the plugs were in and it had slipped in gear, but we shall see...
The more I look at the old gears the more I sense
Someone tried and ( epically failed) to do big fast power wheelies
It looks like they've been saving the clutch for another day doesn't it 🤣😂
Morning. Defiantly a good replacement, does it solve the problem though.
That's the annoying bit.... you can't really test it in anger with load on the engine till you take it out on the road again 🤣😂😅
Dude if you can’t turn that input shaft with the box in neutral you have a big problem. You can’t turn the clutch hub because as you correctly stated, it is meshed to the crankshaft. But the gearbox input shaft is connected to nothing at this point and even if it’s not in neutral, you should be able to turn the shaft. Check that you don’t have 2 gears engaged at the same time somehow. Something is locking that shaft up.
Yeah, I thinkni had it in gear on the bench as I can spin the rear wheel and select gears. The engine is back in frame, so was hoping I hadn't messed it up 🤣😂
If you cannot rotate the shaft you have a problem.. If you remember when you removed the nut from the clutch
you have to hold the clutch boss to stop it rotating...
But I couldn't rotate the gearbox by hand when I was taking it apart either... I think it should be fine... 🤔
Actually, somebody else has mentioned this as well... bugger, have I done something wrong I wonder... 🤔🙁
I just went back and checked the footage again. Without the clutch hub fitted, the gearbox spins quite happily. Once the clutch hub is fitted, it didn't and that was with the plugs in as well so full compression. I wouldn't have thought you'd be able to rotate it by hand at that point as the clutch hub is connected to the crank. Am I wrong? I'm getting worried now as rhe engine went back in the bike yesterday!!
@@QuickBikes The shafts should be free to rotate When I built my XJR you rotate the shaft and check you have gears by rotating the shift drum. Trying to help mate. Please check before you go any further
@@QuickBikes when you had the gears in the case before you assembled the bottom case did the shafts rotate by hand. They should still when the cases are bolted together .It’s the clutch that connects the engine and gearbox.
At 28:30 I was just like ahhh finally it’s not just me that has to decipher the cryptographic text in those manuals 😂 I swear they type things and decide it’s too easy so search a thesaurus to make it’s almost impossible to understand, also these key parts never have pictures or diagrams!!!!!!
Hehehe... annoying init 🤣😂😅
There's never the picture that you want and when there is one, ots a 40 year old newspaper photo 🤣
guess that new jetting means the ZZr isn't Euro 7 compliant? PMSL
Errors.... probably not 🤣😂😅