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First KZ project…. 1980 KZ1000

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06 Dec 2016 18:50 #749691 by JOE MKII
Replied by JOE MKII on topic First KZ project…. 1980 KZ1000
Received the tranny today, looks good, I will check the few clearances I can that are in the manual. I think it was a fair deal,
The shipping was a bit sketchy, it was fast but it looked like the box was drop kicked across the country.
It was packed in dirty old shirts and socks, they were really really dirty. Not that it matters it all has to be cleaned but this was one of the worst packing jobs I have yet to receive!! I was glad it was all there and undamaged,
Next up is to get some gaskets and seals.

Do most here reuse the case half bolts or should they be replaced? They came off hard, felt like they twisted a bit.


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I believe its called "Oppositional Defiance Disorder"

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  • SWest
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  • 10 22 2014
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06 Dec 2016 19:06 #749696 by SWest
Replied by SWest on topic First KZ project…. 1980 KZ1000
They should be reuseable. At that price they should have spent a few bucks on the shipping prep.
Steve

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06 Dec 2016 19:33 #749699 by JOE MKII
Replied by JOE MKII on topic First KZ project…. 1980 KZ1000
Yep, thats what I thought.
Shipping to me, here in Wisconsin, was $52.00 bucks and from the stuff I have shipped recently it was an ok price, but I could never let my name be on something packed that bad!!
It wasn't like old greasy shop rags.., It had a certain going through someone else's dirty laundry feel to it…. :sick:

I believe its called "Oppositional Defiance Disorder"

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06 Dec 2016 19:39 #749700 by SWest
Replied by SWest on topic First KZ project…. 1980 KZ1000
Did he charge you $83.33 shipping? I'd give him a D- for that. :angry:
Steve

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06 Dec 2016 20:24 #749709 by spdygon
Replied by spdygon on topic First KZ project…. 1980 KZ1000
I clear all the threaded holes with a tap and use a wire wheel on the threaded bolts

1982 GS1000sz Katana ( #15...17K Miles)
1982 GS1000sz Katana ( # 297....7100k Miles)
1978 Kz1000 Z1R. 10K Miles1
1978 kz1000 z1r 27k miles
1977 KZ 1000 A ( Project ) 54K Miles
1976 Kz900A4 (Red)21K miles
1976 Kz900A4 ( Red)7500 miles
1974 Z1 900 project

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01 Jan 2017 12:24 #751085 by JOE MKII
Replied by JOE MKII on topic First KZ project…. 1980 KZ1000
Cleaned the top case , cleaned all the threads, cleaned and visually inspected the tranny i got off e-bay. Looks good, I will run through the checks outlined in the manual for clearances and such. The gears and dogs look great, the gears are nice and tight when engaged so don't expect it will be out of tolerance.
Cleaned all the bearings and oiled them , very smooth and quiet operation.
Hoping to button it up in the next week or so depending on my work load,

The cases where the output shaft rides that was scarred up I polished lightly with 1500 grit to smooth it out put the hearing from the new tranny in place and shined a light to see if there were any gaps. looked really good, so no major damaged that I can see to the cases that would cause problems.
I may use a tiny drop of bearing retainer on both sides of the cases when assembling to ensure a good fit….
Do you guys think thats a good idea??
Anything I should know thats not in the manual or obvious that I should be aware of?

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I believe its called "Oppositional Defiance Disorder"

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01 Jan 2017 13:02 #751091 by SWest

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02 Jan 2017 05:22 #751148 by rrsmsw9999
Replied by rrsmsw9999 on topic First KZ project…. 1980 KZ1000
Follow the manual and you will be fine. BTW I have only seen a couple of instances of worn KZ tranny gears. Usually, if broken, it's shift forks or the bearings. Also if your model has the Kaw neutral finder you will not be able to hand shift to second or above and set the drum correctly before assembly. Good luck. R

1980 KZ 1000E2
Crashed 6/2016

1980 KZ550A
Sold 3/2016

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02 Jan 2017 11:32 #751168 by JOE MKII
Replied by JOE MKII on topic First KZ project…. 1980 KZ1000
All the other parts, forks, shift rods, ECT are in good shape. It all seems pretty straight forward at this point.
Looking forward to getting this done and moving on to other parts of this refresh project,

I did receive some new in the package clutch springs wit the tranny, they are labeled for kx125, I have not measured them yet.
Is tis a common swap or a like for like replacement?

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02 Jan 2017 13:46 #751177 by JOE MKII
Replied by JOE MKII on topic First KZ project…. 1980 KZ1000

rrsmsw9999 wrote: . Also if your model has the Kaw neutral finder you will not be able to hand shift to second or above and set the drum correctly before assembly. Good luck. R


Does this mean there is no way to check engagement and run it through the gears while its on the bench?
I played around with it all afternoon checking and cleaning getting ready to button it up, but I see (I think I see) that it will not shift past neutral on the bench.

:unsure: Don't want to screw this up.
I have been reading and re reading the Kawasaki manual and the clymers manual but I feel a bit dyslexic at the moment.

I believe its called "Oppositional Defiance Disorder"

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02 Jan 2017 16:35 #751197 by JOE MKII
Replied by JOE MKII on topic First KZ project…. 1980 KZ1000
From all the searches I did it seems you put the tranny in neutral place the drum and shift forks at neutral and hope for the best .... :blink:

The manual seems to assume this as did the posts I have read .

If this is incorrect PLEASE let me know :)

Thanks!!

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02 Jan 2017 17:18 #751209 by SWest
The following user(s) said Thank You: JOE MKII

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