DON'T HAVE ANY IDEA WHAT'S WRONG !

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ARCHIVE_djtrexishurr

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Schematics

Does anyone know if there is a viewable version of the schematics for a 1996 zl600 online?
 
hey guys !

really stumped on this one ! dad & i, got his zl up & running yesterday, after doing a valve adjustment. it really made a difference ! the bike is running awesome !

dad was so happy, that we decided to put a few miles on the bikes ! we rode that scenic route that i was telling wuputt, & mark about . we had lots of fun running the bikes on this road ! going around the curves & straitaways was a blast, however dad noticed a vibration coming from the bike. at first, we thought, " maybe the rear tire" , but after awhile, i noticed when we came to a stop, & when dad started moving, his engine was slugish, & the rear tire would bounce, once the bike was moving, it stopped bouncing. " i thought he was not getting into first gear, & starting in a higher gear !"

dad assured me that he was indeed starting in first gear. we also noticed a weird noise coming from the drivetrain. we made it home, & decided to tear the bike down to find out what this problem is ! well, we still dont know, because we can not get the swingarm off the bike !!!! we followed the manual & did everything it said, but the swingarm will not come off !

now we are at a standstill, we do not know what is causing the vibration, & dont know why the swingarm will not come off ! does anyone know if the manual is lacking some directions, like maybe a hidden bolt or something ??? & does anyone have any idea what could be causing the engine to bogg down in first, trying to get this thing to move ???? any help, suggestions, tips, or answers, would greatly be appreciated !

dad is wondering if something broke somewhere in the final drive system.

thanks ! CHRIS & MARTY
 
I haven't a clue Chris. This is the first for a problem like this. Read the manual thorughly and have another shot at the swing arm.

Is the final drive unit spinning free and full of oil?

Are the drive shaft joints free?

Rear brakes hanging?

Let us know what you find. If you need to you can always trailer the bike down here.
 
Rear brakes hanging?
Click to expand...

Thats what it sounds like to me Chris! I would put er back together. I have NEVER heard of any probs with the pumpkin or shaft on a Kaw! (not just ZL's, All Kaw shafties)
 
dont think it's the rear brakes hanging ! before we tore the bike down, we put it on a lift, & spun the rear wheel ! spun freely, but heard a noise come from shaft. wont have a chance to work on it tonight, i'm riding ELEANOR out to vfrman's house, to help him adjust the valves on his interceptor.
i'll get back to it tomorrow morning ! i'm going to pay special attention to the u-joint at the front of driveshaft . CHRIS :cool10:
 
After you drop the swingarm from the pivots at the front, pull back the rubber boot that covers the joint to the front bevel, so that you can see the prop shaft. Somewhere around the larger (propshaft) diameter, that slides onto the splines in the front bevel box, there is a tiny hole (rotate shaft untill you find it) Insert a tiny allen key (or small punch or similar) and push. The shaft should then slide backwards.
There is a spring loaded pin holding the shaft in place. PLACE A LARGE SHEET OF WHITE PAPER (or similar) ON THE GROUND to catch the tiny pin otherwise you WILL lose it when you try to juggle the swingarm and shaft and catch the pin at the same time.

Hope this helps.

For what it's worth, sounds like brakes to me too.

KK
 
wuputt said:
Thats what it sounds like to me Chris! I would put er back together. I have NEVER heard of any probs with the pumpkin or shaft on a Kaw! (not just ZL's, All Kaw shafties)
Click to expand...

I aggree
They don't call me Kawasaki-krazy for nothing....I have only ever had shaft drive Kawi's of all types for far more years than I care to remember and NEVER had a problem with ANY of the drive components

But then....there's always a first time......

KK
 
Hey Chris, tell Marty to quit thrashing on that poor Kaw so much!! :stir: :rotf: :rotf: :nonono:
 
thanks kk, & wuputt ! i'll let dad know that he should'nt thrash on his bike so hard ! but, he has to to keep up with me ! :rotf:

with all due respect, i do not want to put it back together, not knowing what's wrong ! i know at this point, that is definately not the brakes. the noise still exists with the rear brakes off the bike !!

i'll keep you posted as to what i find
 
hat to burst anyone's bubble about no drive shaft problems but I have heard of a few problems on the Kawasaki Voyager that dealt with the u-joint. Not real sure exactly what it entailed but just reinforces that problems do exist.
 
thanks furchin ! i knew someone out there has had some probs with the drivetrain. i'll bet that is the prob. with dads bike
 
Damn! my bubble done been busted! :rotf: :rotf:

Hope it isnt anything too serious Chris, by the way I have a shaft in the garage if you need it!

Whole swingarm for that matter!
 
thanks wuputt !!! i'll let you know if i need it !! CHRIS :cool10:
 
U-joints on a car can act like what you are describing. Possibly a previous owner could have let the fluid get low. Or hey "Bad parts happen!" Theres a T-shirt for ya MOAB!
 
good suggestion moab ! i like it ! i'll have to come up with some graffics to go along with"" bad parts happen"

dont want people to look at me funny, or think i need viagra ! you all know how people's minds like to wander !!! :rotf: CHRIS
 
PERSISTANCE PAYS OFF !!!!!

the prob. is in the middle drive system. the freeplay (backlash) is supposed to be, i think, between 17 & no greater than 19 thousands of an inch. well, i do not know the exact measurement, but i dont think it's supposed to move almost a full inch.

so, that tells me that the gears are severely out of adjustment ! i'm going to pull the middle drive system completely off the bike, & check the gears.

i have a feeling that it is not going to be a pretty sight, when i get it opened up !

I AM BIDDING ON A MIDDLE DRIVE SYSTEM ON EBAY !!! for parts & or, swap the whole damn thing out !

CHRIS :cool10:
 
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