kz900 strange engine noise
- OldSchoolHr
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Re: kz900 strange engine noise
11 Nov 2009 08:14 - 11 Nov 2009 08:15
larrycavan wrote:
This is what I found when I opened it.
Cam chain is rusted on one place. Maybe its been knocking. Also, I found a marks from camchain on crankshaft cap :ohmy:
Also, I found a circlip from shift rod is fell of
And my transmission ball bearings are worn out
I dont know what of this, could make a noise like my zed was makeing?
Shake, rattle & roll is the norm for the basket springs in those motors. There is an upgrade kit APE sells with heavy springs, new backing plate and rivets that you weld. Might be worth the piece of mind you'd get from it...
Generally though, those baskets work just fine unless you're severely abusing it at the drag strip every weekend. Scarey to hold that thing in your hand and listen to that rattle but in all honesty, they are solid baskets.
Case looks repairable. A good welder shold be able to handle that.If you end up needing them. They're all over ebay. Look under dragbike. Prices are way down on that sort of thing.
It's your nickle but IMO, you're best bet is tear everything down and go through it carefully. Check your transmission bearings out as well.
If it turns out you had oil problem to top end and cams are worn...holler...I've got several sets of stockers. You can have a set for free if you need them...
This is what I found when I opened it.
Cam chain is rusted on one place. Maybe its been knocking. Also, I found a marks from camchain on crankshaft cap :ohmy:
Also, I found a circlip from shift rod is fell of
And my transmission ball bearings are worn out
I dont know what of this, could make a noise like my zed was makeing?
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www.wix.com/limit2/z900
Last edit: 11 Nov 2009 08:15 by OldSchoolHr.
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- OldSchoolHr
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Re: kz900 strange engine noise
11 Nov 2009 09:10 - 11 Nov 2009 09:13
No, I loose that bolts 
There are no markings inside valve cover.
There are no markings inside valve cover.
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Last edit: 11 Nov 2009 09:13 by OldSchoolHr.
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Re: kz900 strange engine noise
11 Nov 2009 09:24 - 11 Nov 2009 09:29
Transmission gears are like new but bearings are worn.
So I bought all bearings inside engine.
- 2 ball bearings for input and output shaft
- 2 needle bearings with bushings for input and output shaft
- 1 needle bearing with bushing for clutch basket
- 1 needle bearing for starter clutch gear
- output shaft
- starter clutch assembly
...
All of this parts I found at www.kawasakinosparts.com/index.php
Prices there, are lowest I could find.
Also I bought clutch basket rebuild kit, springs and rivets, from Ape. Does anyone knew procedure for rebuilding cluth basket? I thought that I saw some posts with pictures of that on this forum, but I cant find it now.
So I bought all bearings inside engine.
- 2 ball bearings for input and output shaft
- 2 needle bearings with bushings for input and output shaft
- 1 needle bearing with bushing for clutch basket
- 1 needle bearing for starter clutch gear
- output shaft
- starter clutch assembly
...
All of this parts I found at www.kawasakinosparts.com/index.php
Prices there, are lowest I could find.
Also I bought clutch basket rebuild kit, springs and rivets, from Ape. Does anyone knew procedure for rebuilding cluth basket? I thought that I saw some posts with pictures of that on this forum, but I cant find it now.
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www.wix.com/limit2/z900
Last edit: 11 Nov 2009 09:29 by OldSchoolHr.
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Re: kz900 strange engine noise
12 Nov 2009 06:16
Transmission is done.
I am just waiting ape kit to rebuild clutch basket and engine can be assembled.
I am just waiting ape kit to rebuild clutch basket and engine can be assembled.
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- OldSchoolHr
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Re: kz900 strange engine noise
17 Nov 2009 12:54
I received APE clutch basket kit and already disassemble
clutch basket. Tomorrow I will take it to the machine shop
to expand rivet holes and to press rivets in. I am only concerned about this heavy duty springs. Original springs
are 3*thiner and 3*thicker and this springs in APE kit are
all thicker. I dont know how it will be shown in practice
Whether the clutch would have strong shocks or something
else??
Is there anyone on the forum to have some experience with heavy duty clutch?
clutch basket. Tomorrow I will take it to the machine shop
to expand rivet holes and to press rivets in. I am only concerned about this heavy duty springs. Original springs
are 3*thiner and 3*thicker and this springs in APE kit are
all thicker. I dont know how it will be shown in practice
Whether the clutch would have strong shocks or something
else??
Is there anyone on the forum to have some experience with heavy duty clutch?
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www.wix.com/limit2/z900
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- OldSchoolHr
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Re: kz900 strange engine noise
14 Dec 2009 08:49
Clutch basket is done. I didnt weld it, just put new rivets. Heavy duty springs are longer for 0.5mm and there is no play in those springs anymore
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Re: kz900 strange engine noise
14 Dec 2009 09:01
In the meanwhile I have done just a little bit more of polishing. When I finished with my engine , people will have to wear welding goggles when they looked into the engine :laugh:
Also I made some special tools. Clutch basket and alternator rotor holder tool.
Also I made some special tools. Clutch basket and alternator rotor holder tool.
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Re: kz900 strange engine noise
14 Dec 2009 09:13
Next is rebuilding of camchain tensioner. I replaced tensioner shaft, bearing and bearing bushing.
Also, replaced complete starter clutch assembly.
...and rebuild starter motor...
...new rubber and new cables on alternator stator.
...weld 2 new nipples on alternator cover, and little more of grinding and polishing :silly:
Also, replaced complete starter clutch assembly.
...and rebuild starter motor...
...new rubber and new cables on alternator stator.
...weld 2 new nipples on alternator cover, and little more of grinding and polishing :silly:
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Re: kz900 strange engine noise
14 Dec 2009 09:19
Then I throw myself on assembling this poor old engine.
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Re: kz900 strange engine noise
14 Dec 2009 09:31
and finaly got this.
Engine first start was almost to easy. I kicked kickstarter few times without contact, then I turn the key, open chocke and start engine with kickstarter. It start from first attempt.
Then I try starting it with starter motor, and it start in a sec.
Engine first start was almost to easy. I kicked kickstarter few times without contact, then I turn the key, open chocke and start engine with kickstarter. It start from first attempt.
Then I try starting it with starter motor, and it start in a sec.
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