| Welcome to the Kawasaki Owners Club. We hope you enjoy your visit. CLICK here to Join Kawasaki Owners Club! If you're already a member please log in to your account to access all of our features: |
| Z650 jumping out of gear | |
|---|---|
| Topic Started: Apr 15 2011, 06:54 PM (344 Views) | |
| tomgillson | Apr 15 2011, 06:54 PM Post #1 |
|
Member
|
Evening all, After picking up my '76 Z650 from my sister, it felt as though the rear wheel bearing were gone, but it turns out that it is something more sinister - poorly gearbox. What it does is feels like it is attempting to jump out of gear when moderate power is applied, just normal cruising is alright. It does it pretty much in every gear, but ridden normally it's smooth........ I've had a look in the trusty Haynes and it's an engine our job to get at the gearbox, is that right? And it's a 5 spanner so I'm doomed  Thankfully it's a very lean machine so my ideais to get the engine out myself and then get the gearbox done professionally.......... Gutted though!!!!!!! |
 |
 
|
| hugojose | Apr 15 2011, 06:58 PM Post #2 |
Humble Motorcyclist
|
You sure is not related to drive chain or sprokets? |
|
|
|
| tomgillson | Apr 15 2011, 09:03 PM Post #3 |
|
Member
|
I'll check when I get it back tomorrow, but the mechanics reckon that they have had the sprockets off and checked them........... |
|
|
|
| hugojose | Apr 16 2011, 12:57 AM Post #4 |
|
Humble Motorcyclist
|
There is a cushy drive in back. Any chance it may have disintegrated? |
|
|
|
| tomgillson | Apr 16 2011, 07:55 AM Post #5 |
|
Member
|
I was thinking exactly the same thing, it hadn't been ridden and kept in dry garage so very possible. Going to pick up shortly and then a very slow ride home.......... I'm keeping the faith guys, thanks for all your tips. Will get the back wheel out (gotta take exhaust system off to get it on paddock stand though  ) and check the Cush drive.....I've got a poorly RGV250 that needs the doctor too, think today is going to be oily  Many thanks again..... |
|
|
|
| tomgillson | Apr 16 2011, 01:41 PM Post #6 |
|
Member
|
It's looking pretty certain it's gearbox jumping out under load...... Someone mentioned to me that if I get the engine out the box can be got at by removing the bottom end if it's placed upside down on the bench, hence no need to strip the top end? Thanks all Tom |
|
|
|
| hugojose | Apr 16 2011, 05:05 PM Post #7 |
|
Humble Motorcyclist
|
Yeap, that is true. For transmission work, my factory manual shows engine upside down with all top end still attached but bottom crankcase out. It it is really jumping gears, and you would know it out of need to re-shit, before you remove engine, at least take off the transmission plate on the left, just to make sure the shifter fork and pivot are in one piece. To inspect in there the sprocket need to be removed. Edited by hugojose, Apr 16 2011, 05:06 PM.
|
|
|
|
| tomgillson | Jan 9 2012, 04:26 PM Post #8 |
|
Member
|
Well peeps, a bit of an update......... Got the engine out of the bike, had to leave front sprocket on unfortunately, hopefully will be able to get that off later. After getting it on the bench and upside down with the sump off here is what I found As you can see if you look really hard, there is what looks to be uneven wear on the 2 gears in the pic. There was also some tiny bits of metal in the filter too. If you have a look at http://www.tomgillson.com/Toms_Site/Bike_Photos/Pages/Z_Restoration.html there are more pics of the beast and where we're up to............ On a side note, I sopke to Z-Power and they informed me that it was very difficult to get new genuine 'box spares. Bummer! Had a quick look on ebay and picked up a complete 20,000 mile gearbox for £45, so hoping to slot that one in. It looks to be in very good nick and hardly any wear at all. The bloke at the breakers was not very happy when I'd handed over my money and opened the box to look, he'd have charged me double if he'd have known how good it looked. I've got a friend who is a specialist in Z650's coming over to guide me through the rest, and I've bought the proper Kwak workshop manual from the states for £45 delivered after I got shafted in the dying seconds of one in the UK last week :( Getting there slowly! |
|
|
|
| tomgillson | Jan 9 2012, 07:53 PM Post #9 |
|
Member
|
Sorry about the photo not working, even working in it I get this stuff wrong BTW if anyone can suggest how to hold a front sprocket to get the nut off with the engine out of the bike that would be most welcome too  Cheers! Tom |
|
|
|
| gd4now | Jan 9 2012, 10:05 PM Post #10 |
Member
|
You can make a tool of sorts to remove the countersprocket with the engine out of the frame. This was suggested by a member of another site. If you have some spare chain handy you can make a tool without much trouble. Just get a stout piece of pipe, drill 2 holes in it, wrap the chain around the front sprocket, and run 2 bolts through the chain and pipe (as shown in pic below; note the bolts circled in yellow). Then you can use that to hold the sprocket while you use an impact wrench or breaker bar to loosen the nut. I have attached a pic below
|
|
Old Kaw owners smile alot! 1977 KZ650 B1 Seattle WA | |
|
|
|
| tomgillson | Jan 10 2012, 07:50 PM Post #11 |
|
Member
|
Cheers g4dnow, I used your idea but improvised the pipe for a vice on the bench. it wouldn't budge at 1st, so I heated it up with a blowtorch and away it came without too much bother. I'm definitely going to make a tool though....... Clutch basket is a different story and after much heating and breaker bar action (using proper basket holding tool) that wouldn't budge, and there are a couple of marks where it looks like someone had had a go previously, nothing serious though. Might have to try again, or cut it off very gently with my dremel thingy. I'l most likely be replacing that in any case......... Thanks for all the input peeps, clutch basket removal anyone? 
|
|
|
|
| tomgillson | Feb 5 2012, 12:48 PM Post #12 |
|
Member
|
Have managed to to get the clutch basket off, had to take the engine down to a local bike shop, but they did it for free and pulled the flywheel off too. Then back to the garage and loosened all the rest of the crankcase bolts. Each one's loctite had done it's job and they all came out safely :) Bottom of case came off and I could get the primary drive out and then lift the gearbox shafts out and put the 2nd hand ones, which look to be in excellent condition, straight in. I'm going to do the selector forks and drum another day, we'd done pretty good for one morning. It looks like I'll need a couple of seals and gasket for the crankcases.......... I bought some Granville clear instant gasket for the cases, can anyone confirm if this is any good? Says it is resistant to high temparature, and transmission fluids, I take it that they mean oil??? Thanks all............if you wanna see some pictures they are on www.tomgillson.com Tom |
|
|
|
| 1 user reading this topic (1 Guest and 0 Anonymous) | |
Countersprocket_Tool_Pole.jpg (186.02 KB)| « Previous Topic · Kawasaki Classics · Next Topic » |
12:03 PM Feb 23
