Well, Well, Well...the snow turned to rain by the end of the day like usual. Hopefully it will warm back up enough to ride again.

While I am waiting for the weather to break...

i recieved my Hanyes kawasaki ZX900-1100 manual today. Sweet!

If i hadn't mentioned it before, I was warned that I was receiving some ZX-11 parts mixed in with the parts from...what I didn't expect was that half of the parts were from a ZX-11 including THE MOTOR that I have somehow shoehorned into the zx900 frame. To be specific the motor is most likely from a 1990+ ZX-11 (same 1994 as the other parts) I checked the frame and engine numbers in Haynes. I do not know if the chain will match up, I suppose I could throw it on there to check it out.

So some choice words for those bewildered mindswondering ifan early 90's zx-11 motor willfit in an early eighties frame...YES, but some brackets willneed to befabbed for strengthening the mounting points..... ZX11ZX1100 ZX900Engine Motor Swap
A-1 Frame (US made)
zx-1100 motormotor that is in there isZXT10CE034033
if the motor hadn't thrown a rod through the case, I might as well just left the motor in there and fabbed up some mounts.

Well back to business...
From the looks of it, the carbs may have some trouble fitting under the backbone of the diamond frame. I believe for the early 90's version the started the ram air trend with the airbox in the fairing to tunnel in to the carbs. worse case some fabrication of some runners, but keep in mind that if the carbs were at an angle for production, they most likely need to be at that angle to work in any other application because of the float bowls.

If I keep talking I'll never get anything done....dinner then off to see if the carbs will fit under the frame....To be con't

 

Sounds like a sweet project. Also sounds like you're having fun. Rockin! Keep us updated!

 

Hey, it's been a couple days...
I was tending to the other responsibilites in life, women, oil changes, organizing the garage while it's dry outside.

I did however try a to get the zx-11 carbs on the zx-11 motor...I litereally tried standing on the carbs to get them shoehorned into the carb intake boots but no luck. I believe that you may be able to get the carbs to fit if you assembled them on the motor before putting it in the frame...but I am just about done entertaining the ZX-11 motor for now.

I haven't touched the bike in a couple days....
Some E-bay sniper got me for the tranny I was buying...pist.
I am really clost to just bucking up and buying a used complete motor, and rebuild the stock motor when I have time...maybe with some extra goodies.

Cheers!

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Did you apply some oil to the boots prior to standing on the carbs?
Good luck in your endeavor. I am sure that you will keep us informed.

 

Yeah, I tried a little WD-40, The angle is just so slightly off that I couldn't get them in. I would have tried to take the carb holder boots off, but I don't think I would be able to get an allen wrench back down to tighten them to the intake runners. I think it's about time to pull that motor anyway it's missing chunks of the crank case.

Cheers

 

Well it's been couple days, I have been working 12 hour days and working on a truck so the ZX900 has been put on the back burner for a little while. I am slowly trying to put together a plan to figure out where to start with this motor. I would like to get to a point where I know I have all the pieces to the motor and where they go. That will allow me to piece the motor back together in order to troubleshoot the transmission.

The to Do list (in no particular order yet)

1. Figure out all the d@mn bolts...what I have, what I don't, if I could find a complete stainless grade 8 replacment set. I do have a little plastic sheet, I can't think of what it is called off the top of my head...but you use it to find diameters of bolts, length of bolts etc...it's very handy. But it doesn't help if you don't know where the bolts go. So It would probably do me some good to sit down and tediously catalog the bolts specifying length, head type, finish, diameter, pitch, and the threaded portion length. Once that is cataloged measure the hole diameter and pitch with bolts I have, measure depth, measure distance from the base of the head to the start of the thread.

2. Clean all the parts of road gunk and oil.

3. Design somthing cheap for an engine stand, it really is a pain trying to get at all this stuff when I have to turn the motor over on the bench etc...

4. perform all the service limit measurements on the tranny gears, dogs, shifter drum

If anyone wants to add a little advice, humor, or encouragement...I am all ears.

Obviously it would be much easier to rebuild a motor if you have the proper tools, space, clean workbench, have all the parts, and know where they go. I can't say I have any of those 100% so I am battling myself and environment as well as the motor.

Just to let you know I am still riding here although it's a little cooler than I'd like.

All this talking makes me want to get back on the motor. So I will.

Cheers.

 

Well, I am in Chicago for the holidays so the ZX900 is waiting for my return. I will be getting back on it when I get back. I have plans to get a welder when I get back, so I can make the engine stand I so desperately need. I am studying up on my Clymers KZ book. So more to come. happy Holidays.

Cheers

 

I always keep up with this thread. This is interesting stuff. If I had the money I'd be doing projects like this. Keep us (me, if no one else) updated.

 

Thanks for the encouragement Deuce. In all honesty I don't have a dime in it. i was lucky to find people that wanted to offload bike parts. Most of the bike parts I get are from people that just don't have the time, space, or money to keep a project going. I don't take on too much, but this was too good to pass up. The extra parts that I got I am selling to get money for this project. These freebee's are out there it just takes a keen ear, a little bit loose jawing and putting what you want out there, someone at sometime will remember what your looking for. However, I have to admit I do have alot of time on my hands and the project obsession where if it doesn't need work it's not worth it, and the cheaper the better.

Well off to the new year and to Maryland in the morning.

Cheers!

 

Alright, back in action. My truck has taken up my attention the last two weeks, so now that it is fixed...back to business.

I believe I have found the problem that may have led the previous owner to tear apart he bottom end. So bear with me and I think some pictures are in order.


You can see the Jagged edge in the middle of the pinion tooth


You can see where the Dogs don't fully engage and fall out of their slot on the pinion








All in all a good excersise in using the macro mode on the camera.

I hope this sheds new light on "Banging through the gears"

Well time to look for a "lightly" used set of pinions, gasket set,RTV, Beer, oil, chili, and a happy ending.

Cheers!