what would you do?? *pics added*

welp, going to the mechanics today to go take pics for you all and to "SEE" for myself what the hell is going on.....
"we" (Darcy, my grade A mechanic and me watching!) tried everything 1st, then just had to "crack" open the cases.... it woulda been GREAT news if it were a snapped gear shaft, as that is repairable.... as it is, what was found, is not.
I don't know the details, but some sort of 1mm bit of bearing matter/metal that lives in the actual case has failed. my mechanic canNOT believe that kawasaki designed it like this or that NO-ONE else has ever had it happen to them (we called around everywhere, and apparently this is the first time it has ever happened???) he thinks all the dealers are keeping their mouths shut about it so Kwak doesn't have to "cover" a design fault.....
anyway, i just got the news this morning on the phone, so i will PEDAL down there (as i have been doing now for a few weeks, thank you for getting me fit 6r )
in all seriousness... I ride like a girl (no offense girls, but i'm not a hoon nutter), yeah, the occassional wheelie here and there, and a few burn outs on BALD tyres....but F@RCK me, it's a gawd-DAMN sportsbike!!! i really thought i baby-ed (babied?) the piece of shit ever since i got it a mere 40,000-ish Kay's ago (I had planned on keeping this stupid thing for a few good years, as I did all the research B4 i bought it. I don't believe in buying the latest greatest newest weapon.-well, i would, but $$$- I like the classics, and I wanted to one day say, yeah, i've had this beautiful bike for decades, but damn, two years, and....).... and yeah, i did ride it high in the rev range, but again, is it not a bike that redlines at..... oh hell with it, too pissed atm...
I mean, i serviced it religiously. always changed the oil before it was anywhere near dark honey colored! changed the oil filter every change as well. always the good silkolene stuff.... always changed/checked the air filter. changed plugs when they didn't need it really, etc, etc... it was tenderly loved! except for the tyres.....
LOOK, all I can ask now, is what should I do? I hate motorcycles now. again, thank you for that too, Mr. Kawasaki....
do i get a new motor? (will a '02 636 fit it easy enough?? -may atleast put a little smile on my face- well, it is just thinking about it ) do i sell it as is? (i'll seriously take offers ) i'm just beyond low.... my legs are so sore form riding my push bike everywhere.....

pics to come in a few hours.....
(<---- i seriously am crying as i write this, can't see the keyboard from the the tears now, damn sniffly nose now too, oh, great, snot on the keyboard.. hope kawasaki didn't make my keyboard, it'll probably break if i look at it wrong....)

Last edited by Yankee on Thu Nov 03, 2005 1:44 pm, edited 1 time in total.

Let me get this straight:

A bearing fails that no-one in the history of mankind has ever had fail, and it's Kawasaki's fault because they cast it into the case? At least with Honda's early V4s you could point to insufficient oil feed as a design flaw, but this?

There has to be a reason it failed. Oil starvation due to foreign matter in the oil? Poor filtration of oil leading to ...? Dunno, but bearings don't just fail on their little old lonesome.

Don't get too down. I know it's easy to say, but that's still a real nice bit of kit you have there, even if you have to replace the engine.

Oh yeah, what would I do? I'd find out what caused the problem in the first place if at all possible, and make sure it didn't happen again after I fixed it.

Sorry to hear that yankee.., I feel soooo lucky now that my attempted wheelies "only" cost me a fork seal

But didn't get what you're saying. Is there actually a "non-servicable" part inside the J1 ??? That's no damn good and justifies an "upgrade"

I feel your Pain Marty, but have a coupla beers, kick the cat & move on mate. You know my personal views on the situation so i wont get all "Nanaree" on you here.
But mate its Mechanical & sometimes the Shit just Breaks. Just becuase you've had a "freak" failure doesn't mean they are a "Crap" bike.
I'd prowl ebay for a motor from a similar model & jerk it in.
You & the 6r have come along way with your riding in a pretty short time so too sell or not too sell seems a bit "short sighted" imho.
cheers Brett

kick the cat & move on mate.

HAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHA


If it's a Siamese, put your Blundstone's on first!

Err what's the problem??? Just rebuild the motor!

Sorry for you man!

Anyway how about machining and rebushing that part?

A decent machine engineering shop will/should be able to do something.

Don't give up hope lil' buddy it will come good I know it will.

Try contacting Kawasaki Aus about the problem. A long shot but a written letter will make you feel better. Keep pictures of the work done by your mech and metal evidence and reciepts.

Source another 'newer' from the wreckers with low K's. I know the bike will never be the same but sh*t happens. At least you have a spare motor!



snr

yeh cant it be welded and machined, I cant see how a bearing thats broken cant be replaced because thats what engineering shops do.

Yankee, you may have babied the thing, but what about the previous owner?

Find out what the thing is going to cost to get it fixed, the ring all of the wreckers you can (including the ones interstate) and find out what a replacement engine is worth.

Go with the cheaper option.

here yankee saved you the search go across the road with a photo/part in your hand and see if they have a fitter who can weld the sucker up good as new.

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All Your Engine Reconditioning Needs

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They can....but won't guarentee the work. The crank you can get it machined and use different 'caps'. Don't get it metal sprayed, as there is no guarentee on that. That's how I see it.

yeh cant it be welded and machined, I cant see how a bearing thats broken cant be replaced because thats what engineering shops do.

Comes down to money! Spend as much money to fix the crank or buy a another motor. If the crank is getting machined and put togther and run in smoothly (the way I'd go) is peace of mind.

Another motor.............mmmmmm could happen this one too.
Choices choices

snr

my understanding of this is a peice of the engine casing has broken away where the clutch actuater is and need to be welded up but i will wait for the photos.

ok, check it out.... my 1st post i didn't know what was going on, now i do......
the actual engine case, right where the clutch shaft goes into the engine, well, that "wall" is maybe 1mm thick. it's a half circle (due to the engine case being in two halves )
anyway, that little bitch, just POPPED right off! the clearances are TIGHT, i mean, i couldn't even fit my.... well, you know, in there, and it's damn small!! (sorry, trying to stay light hearted about this!)
so anyway, have a look at the pics, i'll call that machinist of yours Bob (thanks a mil, finger's crossed).... but because of where it is, i mean, this thing is wicked TIGHT... gear on one side of case, RIGHT NEXT TO WALL, and bearing on other side RIGHT NEXT TO WALL!!! i don't know how they could do it? plus it has to be "schmick as" (smooth) cuz it is holding the shaft...... so....
1) hopefully the dude across the street can fix it (welding and sanding?! )
2) "new" motors (23K on clock) $2,600 gotta get both halves obviously, as they are matched sets... if you do that, you need all bearings, gaskets, etc. so may as well get a new engine!! minus the carby's, electrics, etc...
MAN--- eh, have a look at the pics.....

okay, now to answer a few posts....
strika, i hear ya, but i just wish i had the dosh to just rebuild the engine!!
SNR... a 5 year old bike, a "fault" that NO ONE I can find (heaps of on-line forums, calling around, etc... internationally) has had, but me... i don't like my chances there... but hell, worth a try... cheers.
Beryl- just rang... sounds "positive" but he needs to see it (obviously) and he can't make the "TREK" across the street to go have a look, so I gotta somehow get the engine to him to have a FREAKING LOOK... FOR F-SAKE!!! (just tried calling Darcy to have him take it over there... but i doubt that'll happen either!)
Jase- the dude before me, well, even if he rang the things neck (which i have done too)... this particular "failure"... well, what the hell causes an engine case wall to fly off, perfectly around the shaft of the clutch gears??? yeah... engine $2600, labour... whatever.... not getting outta this for under 1/2 what the bike is worth that way.....
and Brett-- you gotta cat mate?!
thanks all for helping me thru this..... too bad it's only just beginning.... back on the phone now....