Dismantling the gearbox (Part 2) - 1990 Kawasaki ZZR1100

[@markwagner909]

Send it to a trans specialist for repairs and have them race cut the dogs. While it’s apart. Shops that focus on drag racing will know who can do this. Several here in the states. You would be amazed at precision shifts!! Your turbo friend should know as well. Good luck!! Enjoying the show. Been here since the start.

[@QuickBikes]

I'm not really going down that path matey, I just want a stock, reliable bike I can use. Ill probably project it at some point and then anything goes 😁 Thanks for sticking with us dude, it's very much appreciated 👍

[@MichaelZZRrider]

Just great videos mate. I have been riding these things for years and I am seeing inside the engine/gearbox for the first time. Good luck with the rest of it.

[@QuickBikes]

Thank you matey much appreciated and thanks for watching 😁👍

[@dermotkelly2289]

Good job. I used to strip down industrial gearboxes many years ago at Ford's. At first I used to take as many photo's as possible because they were a nightmare to put back lol!

[@QuickBikes]

I'll bet matey. I'm sure you could do this one in your sleep, but doingnit for the first timenis both nerve racking and kinda cool all at rhe same time. I like mechanical stuff like this 😁👍

[@simongroot7147]

To get the clutch basket off you can hold it with your hand and then put the impact gun on it, never had a problem doing it like that. Tool is only needed for assembly.

[@QuickBikes]

Ah right, I just went by the manual matey, but I've got one now anyways 😁👍

[@onomehtenialb]

Agreed! Ive held the basket in place with a big flat ended screw driver & the impact wrench took the nut off lickety split. No reason to manufacture a clutch tool.

[@jeffatkinson690]

Still enjoying this, I like the way you methodically work and bag up individual parts. keep up the good work

[@QuickBikes]

Thank you matey, and thanks for sticking with it 👍

[@qivarebil2149]

Just count the teeth, and check against the transmission specs. It should tell You how many teeth the 5th gear has. But, hey! I just checked it for You! Input gear on fifth, has 26 teeth, output has 30. So there You go! You're doing great! Keep up the good work! 👍

[@QuickBikes]

Thank you matey 👍

[@basilwatson1]

he is doing all right, AND he is using a Haynes manual. big respect.

[@Shinysideup]

Doing a good job Quicky, I know it’s pain but you seen to be enjoying it.

[@QuickBikes]

I am matey, I really am... I kinda get the just of what stuff does and I can see how it would work now. It would be great if it was all familiar, but this is how I learn, by having a go basically 😁👍

[@Michael_Milne]

When my 1991 ZZR600 gearbox kept jumping out of second it was worn dogs. When I split a later model for parts, I found that kawasaki had also made the detent plate on the end of the selector drum more aggressively ramped. Maybe that helped to prevent the wear from taking place on future models...

[@QuickBikes]

Yeah possibly I guess. I know they redesigned the D version but still looking to see what they actually changed...

[@ericknoeller434]

Great video learning a bunch...still undecided if I want to attempt replacing dogs on 02 zx6r. 😂

[@pauls6157]

Doing a great job 👍, the inner workings are cleaner than your mug ☕️😂🇬🇧

[@QuickBikes]

The floor is cleaner than my mug 🤣😂😅, but on the up side, I don't get poorly very often 😉 👍

[@mattmcevaddy]

great video and attention to detail. looking forward to seeing how you resolve this!

[@QuickBikes]

Thanks for watching matey 👍

[@markfava4127]

To remove the clutch basket you need to paul the clutch collar in the centre off the clutch with. To bolt hope that help love the show

[@QuickBikes]

Thanks for chippingnin matey and for watching 😁👍

[@Pianissimo1970]

While you're in there, remember to fix the chain tensioner, with the tools you have its easy to make one yourself

[@QuickBikes]

I checked rhe clutch pressure plate and there's absolutely no new nicks in it anywhere... I'm getting some measurements whilst it's out of the bike and will make.one at some point, but whilstnuts all behaving itself it can just go back in for now. I'm on a bit if a deadline with this bike as I currently have NO transport at all... 😁

[@simongroot7147]

The way you are looking at the transmission, the gears are from Left to Right (22:53) 2nd, 6th, 3rd, 4th, 5th, 1st. The 'double gear on the input shaft with the forward facing selector fork is 3/4. The dogs on 5th particularly are buggered. If it had broken a tooth off, it would most likely still engage (for a short time before the gear stripped completely which would lock the transmission completely) but there would be a loud click every time the missing tooth passed the other gear. They do not last very long at all with a broken tooth.....

[@QuickBikes]

Sh right, good to know matey, thank you. The gear teeth themselves look really good but the the dogs are seriously worn I believe and there's rub marks on the selector forks as well 🤔

[@andyjrichie6709]

Great video, great to see someone else getting dirty, new to channel

[@QuickBikes]

Welcome to the madhouse matey, hopefully you like it 😁 👍

[@andyjrichie6709]

@@QuickBikes I love a mad house, keeps me sain

[@RaceJan]

Just get on with it then... :-) (just kidding, love every second of these vids where you're muttering and grinning to yourself... LOL)

[@QuickBikes]

Hehehe.... anybody passing by must think I'm mad 🤪🤣😂

[@garyyorke1080]

Well your now at the intimate stage of accessing your gearbox internals . The ole fairy tale book hasn't been too bad to follow so well done . Slight wear on the forks as you say but those gear dogs are muntered that would explain why it wont move smoothly. A swap out with new cogs and time to rebuild it

[@QuickBikes]

I'm looking forward to seeing the state of the new gearbox which has arrived today. Basically all the best bits are going back in it 😁👍

[@valvegeek]

Very interesting - been away so playing catch-up - but yeah that looks like it ... 👍😁

[@QuickBikes]

You'd think, wouldn't you... 🤣😂

[@troywee4774]

good stuff mate, getting there! cheers.

[@QuickBikes]

Slowly but surely matey 👍

[@_marcus_does_]

Quality Quicky

[@QuickBikes]

Thank you matey 👍

[@myturkishlife1777]

Your doing a great job, 👍

[@QuickBikes]

Thank you matey, it's kinda fun too 😁👍

[@themayorofdipshittery3646]

I’d be inclined to replace the dogs/selector forks, depending on cost, all together while you’re in there, might be the problem with 2nd as well 🤷‍♂️

[@QuickBikes]

I've got a complete gearbox coming matey, so plan on putting all the best bits back in again 😁👍 Hopefully I can avoid another problem in the future that way

[@lardmarc]

Nice tool.

[@QuickBikes]

Tis an awesome thing that I probably didn't need to make anyways 🤣😂

[@simongroot7147]

The removal of the clutch is necessary so you do not have to turn the engine over to rotate the input shaft.

[@QuickBikes]

I think there's a problem here now... I'm sure of it actually, but you'll see in an up coming video... 🤔

[@karlvanboxel561]

She’s gone to the dogs mate! 🤔 undercut dogs r normally cut at 5 degrees corse the trick is getting em all cut evenly as u want even contact wif it mating be-atch 😂😂😂going good mate

[@QuickBikes]

YeH, I'm just going stock for now dude. The new gear looks basically mint with very little wear, so we should be good I reckon 😁👍

[@jasonkristunas9427]

Keep looking it’s in there somewhere!🤣

[@QuickBikes]

Hehehe...

[@davemason6273]

Blimey! Those dogs are made of cheese, sakakaki economics keeping costs down, expecting people to use the clutch! Mind you they sold a lot of em.

[@QuickBikes]

Pretty sure this is caused by somebody who doesn't know how to change gear properly... 🤣😂

[@davemason6273]

@@QuickBikes used to annoy me the ACU teaches kids to change without the clutch ONLY

[@QuickBikes]

Hehehe... they probably only teach em to shift with a quick shifter now 🤣😂😅

[@markwagner909]

They may be able to repair the dogs with a hard weld then machining. And probably how it’s done in the first place.

[@QuickBikes]

I have a replacement gearbox now matey and not sure a repaired gear would last that long. It's just easier in this case to swap it out as quite a few dogs are knackered... 🤔

[@Micky748-r7u]

Why you making a tool and using it in the same video, that’s two videos worth right there but you knew that didn’t you 😂😂

[@QuickBikes]

🤣😂😅 and I came up with yhe idea all myself, regardless of what I said in the video 🤣😂

[@QuickBikes]

🤣😂😅

[@stuartfrancis9182]

Hi do you now how I open a GSXS125 engine 😀ps now book of words

[@QuickBikes]

Not sure matey, but I'm pretty sure it involves a BIG hammer 🤣😂

[@simon2knine]

A few more bolts and the gearbox will be out..

[@QuickBikes]

That happened today matey, and I found.... stuff... Video to follow 😁👍

[@simon2knine]

@@QuickBikes Looking forward to the next video..

[@QuickBikes]

Thanks for following along matey 👍

[@wibblywobblyidiotvision]

Those dogs don't look too handy, it has to be said. Does the book of words / book of fairy tales tell you which gear is which?

[@QuickBikes]

It does I just haven't looked it up yet. I know the smallest gear on one shaft is 1st and the largest gear on the other is also 1st, but can't remember which way round it goes 🤣😂😅

[@eddiemizen3703]

Need a little tool🤣🤣

[@QuickBikes]

Dead handy matey 😁

[@grahamhider3754]

👍🤢🏍🔧

[@QuickBikes]

😁