OMR's New Girl.... 1997 Voyager XII (ZG1200-B11)

That is a J motor isn't it ? With a water jacket. What kind of manuals do you have?

Sorry I have questions for your questions.

Contact Jay at APE. He knows all.

OEM manual depicts nothing on this...
Spoke with Carl Leo, on Voyager sites he's the GURU. Truly neat old guy who also happens to own a 1976 KZ900LTD sleeper w/ a 1260 displacement, .400 cams.... :evil:

Speaks with a heavy Tennessee accent, To listen to him tell his story of handing a young blood on his new transformer bike his ass with that old girl is pretty funny,,,,

Anyhoot, turns out you have to pop off the flywheel...

I'll keep all posted (update in the project) in case other voyager owners out there need to accomplish this task...

OMR

Old Man Rock wrote: OEM manual depicts nothing on this...
Spoke with Carl Leo, on Voyager sites he's the GURU. Truly neat old guy who also happens to own a 1976 KZ900LTD sleeper w/ a 1260 displacement, .400 cams.... :evil:

Speaks with a heavy Tennessee accent, To listen to him tell his story of handing a young blood on his new transformer bike his ass with that old girl is pretty funny,,,,

Anyhoot, turns out you have to pop off the flywheel...

I'll keep all posted (update in the project) in case other voyager owners out there need to accomplish this task...

OMR

I hope I never have to split the cases on mine. :woohoo:
I was going to suggest you talk to Carl. I thought I saw you post on the AVA site so you found him anyway. He is a treasure.
You're going to love the ride on the Voyager if you like to travel. It handles better than the KZ (mine, anyways), smooth, neutral steering, light, just a touch of counter steer and it falls into a turn. I'd suggest Progressive springs in the forks and a Superbrace to go with the Progressive shocks on the back. The boots from the OEM rear shocks will fit over the fork tubes to protect them from bugs and grit. For the rear seat officer, you can move the trunk back up to 3" and add some padding between the seat and the grab bars. Makes the seat wider and more comfy on long trips. I can send you some pictures of my trunk extenders if you want. They're easy to make and the original parts can be saved and replaced if you want to. There's a guy on the AVA site that makes a bracket to mount Gold Wing arm rests to the Voyager. I may have to ride out to Phoenix this fall to take a look or maybe pass the flag. The PO of my Voyager lives in the Phoenix area, I could visit him too. Yup, now I have an excuse to go to Valle Del Sol

Hey Tom,

Yup, already did the Progressive front springs, seals, boots and new Progressive rear shocks.... Way better ride,,,, Smooth & Comfy....

I'll have to fab a flywheel puller for it is on there so tight it is ridiculous... Followed Carl's advice by giving it a good whack but no go, damn thing won't budge.

Anyhoot, at this point I have to get it off at what ever cost... (Sanity-Conquest)
All good, I have a couple months (:blink:) until it cools down aka riding season.

OMR

OK, flywheel does have to come off.... Included metric bolts for attachment...

Starter clutch already swapped out... Old one spins both ways by hand... DOH!


Tranny gears, bearings, clutch components, oil pump components etc... all look good.

Cleaning grime off cases/pan while putting her back together... Images to follow etc....

For those that may need.... $14 tool to get the flywheel off, worked like a charm!

Made some progress, almost there....

Starter Clutch replaced, yup old one is toasted...


Engine Cleaned...


Hate Working on oily/greasy/grimed crap....


Carbs cleaned inside & out...


Water Pump Oil Seal.... Seep hole is where she leaked pass seal...


DIY Flywheel holder for 110 ft/lbs torque....

Oops...

Image sizes too large... :pinch:

Made some progress, almost there....

Starter Clutch replaced, yup old one is toasted...


Engine Cleaned...


Hate Working on oily/greasy/grimed crap....


Carbs cleaned inside & out...


Water Pump Oil Seal.... Seep hole is where she leaked pass seal...


DIY Flywheel holder for 110 ft/lbs torque....



Now it's install the exhaust, radiator w/coolant and starter her up....
New Pirelli Route rear tire going on as well!

That looks great. Your wife will love you for all the hard work. :whistle:

Looking good OMR, check out all those hoses, you still have to stuff an air filter in there too :woohoo:

bluej58 wrote: Looking good OMR, check out all those hoses, you still have to stuff an air filter in there too :woohoo:

There is actually 2 airboxes, an upper and a lower. :laugh:
The easy part of reassembly is the smog junk (air injection system). Leave it off and plug the holes. Just like the KZ J motors.