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AAARRGGHHHH Mr Kawasaki!!!
Guinness - 9/9/06 at 06:12 PM

What were you thinking!!!!

I have just spent the day taking my two duff engines apart, keeping all the bits seperate! in order to try to make one good engine.

The plan was to take the gearbox out of one engine A and put it in the second B.

It doesn't fit.

Arrghhh. Both are model C ZZR1100's. The drive gears from the crankshaft to the clutch baskets are different sizes! Can't use the crankshaft from the matching engine as it was damaged by the bearing collapse.

Question is, can I run one half of the gear box from bike A with the other half of the gearbox from bike B and a mix of selector forks (whichever is showing least wear). Or is all this going to end in tears!

(Reason for changing the gearbox was it jumped out of second and third gears)

Oh yeah, joining the crankcase halves, Haynes says "using a suitable sealant" join the two halves. What IS a suitable sealant? I can get Loctite 595 RTV tomorrow, but is there a special sort I should have bought?

Cheers

Mike

smart51 - 9/9/06 at 06:36 PM

2nd and 3rd gears are on splines and bearings. It should be possible to swap them over but if there are some differences, you might be unlucky.

If you are going to swap over the gears, you might want to see what other gear ratios will fit. It is an ideal opportunity to get gear ratios that suit a car rather than making do with what suited the bike.

NigeEss - 9/9/06 at 08:20 PM

Try 'Wellseal", the stuff used for metal mating surfaces on cam carriers such as
the K Series. Most engine reconditioners stock it.

ch1ll1 - 9/9/06 at 08:30 PM

i second that

quote:
Originally posted by NigeEss
Try 'Wellseal", the stuff used for metal mating surfaces on cam carriers such as
the K Series. Most engine reconditioners stock it.


wellseal is great !
about £10 but it works a treat ! ( and gets every where !
make sure you put the lid back on right, or it will be everywhere !

Guinness - 9/9/06 at 08:30 PM

Thanks lads.

Found out I can disassemble the clutch from the input shaft and re-use the original drive gear.

Will try that in the morning.

Mike

Coose - 9/9/06 at 10:48 PM

Use Yamaha Bond - marvellous stuff! It's not cheap though....

Part no. could be ACC-11001-05-01.

G.Man - 10/9/06 at 06:46 AM

you must use a soft non-setting sealant to join the crankcases, as otherwise you will block oilways...

Guinness - 10/9/06 at 07:36 AM

Thanks G

any brand names to look out for?

Mike

Coose - 10/9/06 at 08:45 AM

See my previous post Mike. And only apply the lightest smear as it will compress out of the joint and WILL block oilways....

Guinness - 10/9/06 at 08:56 AM

Thanks Coose

Will be making a diversion up Westgate Hill tomorrow!

Cheers

Mike

Guinness - 10/9/06 at 10:19 AM

Just found out from another forum that not only are parts of the ZZR1100 interchangable with the GPZ900, but also the ZX10!

I have a ZZR1100 crankcase but with a ZX10 crank and clutch basket in it!, with a GPZ900 sump on it!

Mike