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.

They should be reuseable. At that price they should have spent a few bucks on the shipping prep.
Steve

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:

Did he charge you $83.33 shipping? I'd give him a D- for that.
Steve

I clear all the threaded holes with a tap and use a wire wheel on the threaded bolts

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?

Looks good to me.
Steve

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

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?

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.

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.

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!!

That's right.
Steve