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Old 09-20-2011, 10:16 PM   #1
fastcar302
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Bottom end assembly issues on ZX14

I am going to be splitting the cases on a Zx14 to do some transmission work soon, but before I do I wanted to get some opinions on the assembly procedure for this particular bike. I've rebuilt dozens of sportbike motors on R6's, R1's, Gsxr 600's,750's,1000's, Busa's, CBR's, and so on. The one manufacturer I don't have much experience on is Kawasaki. I know what I'm doing and I don't need a how to, just some advise from people who actually have experience with this specific motor. A friend of mine who has worked on some of these motors told me the ZX14 was kind of a pain in the because Kawasaki's bearing color codes don't match and the tolerances were always off due to machining on Kawasaki's behalf. He also mentioned that I would need a bolt stretch gauge. I've never had any problems with this from any other manufacturer so this is new to me. Does any body here have any experience with splitting cases on one of these motors? No speculators please.
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Old 09-20-2011, 10:22 PM   #2
Patrick
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Plastigauge the bearings to verify clearance. Your friend is correct, some of the bearing color codes are incorrect. You'll also want to replace the rod bolts and nuts. Follow the torquing / measuring procedure in the manual. You'll need an accurate caliper and some patience but it's not bad. Not really any different than measuring bolt stretch on Carillo rods.
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Last edited by Patrick; 09-20-2011 at 10:38 PM.
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Old 09-20-2011, 10:31 PM   #3
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Btw, here's a link to the manual if you don't have one:

https://rs523tg.rapidshare.com/#!dow...ice_Manual.pdf
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Old 09-20-2011, 11:01 PM   #4
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watch out for the 2nd gear interlock on the driven gear, there should be at least 3 ball bearings that will fall loose when you seperate it from the countershaft. and when re-assembling, don't use any grease to hold the in place. if all you are doing is tranny work, I don't see why you would need a bolt stretch gauge, rods is a different story.
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Old 09-21-2011, 06:57 AM   #5
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You gonna undercut the tranny?
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Old 09-21-2011, 09:50 AM   #6
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Thanks for the info Patrick and Squanto84. I'm not undercutting the tranny, just replacing damaged parts. I haven't taken it apart yet, but I probably will within the next few days. I just wanted to get an idea of what I was getting into. I don't think anything is wrong with the motor so I shouldn't have to break the rods loose, I just wanted to make sure there were no issues with torquing the case bolts or anything like that.
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Old 09-21-2011, 10:46 AM   #7
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Quote:
Originally Posted by fastcar302 View Post
Thanks for the info Patrick and Squanto84. I'm not undercutting the tranny, just replacing damaged parts. I haven't taken it apart yet, but I probably will within the next few days. I just wanted to get an idea of what I was getting into. I don't think anything is wrong with the motor so I shouldn't have to break the rods loose, I just wanted to make sure there were no issues with torquing the case bolts or anything like that.
Nope, nothing special there.
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Old 09-21-2011, 12:37 PM   #8
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Shift fork issue?
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Old 09-21-2011, 01:24 PM   #9
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-Thanks for your help Patrick!

-I'm not sure what's wrong with the tranny yet, but it sounds like more than a bent shift fork based on how he described the noise. He should be dropping it off today so I can take a look at it.
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