The strangest of noises

[bogan]

Indeed!!!! a quick torque test on the output shaft (lunchtime sprocket removal!!!) and hopefully I'll be able to decipher which end I'm dealing with! god its a pain, but i do love 19,500rpm faaaar too much to think of selling it, at least until I grow up!!!

Yeh I've ridden one a mate had, many many revs! which is a nicely impractical laugh. Good luck with the fix.

[the bear zxr]

without trying to sound too changeabout..... this may be a clutch issue... unless i can come up with a definitive answer, I'll just let you know how the clutch renewal goes, and then go from there!

[Drew]

The bearing will not come out without the cases being split.

The shape of the case castings holds the transmission bearings in place.

What he said.

There doesn't seem to be a retaining clip/half ring to hold the bearing in there, on the exploded picture I found, so I would assume it's located by the casings them selves.

Best starting point, drain the oil and see how much metal comes out with it. You might need to pull the sump off too, to be sure.

A buggered output shaft bearing, would normally cause the seal to fail and for oil to leak.

[fridayflash]

good plan, and easy to eliminate fingers x'd eh.
as katman said earlier, your only way to get that output shaft out is to remove and split...ouch!
good luck Herr Thoeming

[the bear zxr]

I'm running on the assumption that the bearing is a press fit with sprocket tension as its only holders, I got an ORIGINAL workshop manual with the bike (a shame the only ever came in japanese; i can't read it! ) not a photocopy; so the pictures are crystal; and there isn't even a hint of an outer lip on the bearing sleeve.... I could be wrong, but they seem to have drawn every other conceivable detail on these diagrams..

[Katman]

on a hill................

how do you crash start a bike......?

Yes, a bike will roll downhill if it's in gear with the motor not running if the clutch lever is pulled in.

As soon as the clutch lever is released the engine either starts or the bike grinds to a halt rather quickly.

So how have you determined that the noise is still there when the motor is in gear with the engine not running and the clutch lever is not pulled in?

[Katman]

I'm running on the assumption that the bearing is a press fit with sprocket tension as its only holders, I got an ORIGINAL workshop manual with the bike (a shame the only ever came in japanese; i can't read it! ) not a photocopy; so the pictures are crystal; and there isn't even a hint of an outer lip on the bearing sleeve.... I could be wrong, but they seem to have drawn every other conceivable detail on these diagrams..

Your assumption is wrong.

[Drew]

I'm running on the assumption that the bearing is a press fit with sprocket tension as its only holders, I got an ORIGINAL workshop manual with the bike (a shame the only ever came in japanese; i can't read it! ) not a photocopy; so the pictures are crystal; and there isn't even a hint of an outer lip on the bearing sleeve.... I could be wrong, but they seem to have drawn every other conceivable detail on these diagrams..

I've never encountered a gearbox bearing that was a press fit. They literally fall off and cause all sorts of problems when you have the box shafts in hand. It could be different though, I don't think I've ever done a Kawasaki.

There should be a seal between the bearing and the sprocket. It will come out if you're careful with a screw driver. For the sake of $15 from Seal Imports, do that and have a look at the bearing, you'll be able to see it clearly.

[Katman]

Just checked the workshop manual.

The output shaft bearing is located in the crankcases by a C clip that sits in a slot on the outside surface of the outer race of the bearing and the inside surface of the machined bearing housing of the crankcase.

It ain't going to come out without splitting the cases.

[the bear zxr]

Yes, a bike will roll downhill if it's in gear with the motor not running if the clutch lever is pulled in.

As soon as the clutch lever is released the engine either starts or the bike grinds to a halt rather quickly.

So how have you determined that the noise is still there when the motor is in gear with the engine not running and the clutch lever is not pulled in?

It does keep going for a bit, remember we're talking a 250 here, not a big thumper...

[the bear zxr]

Just checked the workshop manual.

The output shaft bearing is located in the crankcases by a C clip that sits in a slot on the outside surface of the outer race of the bearing and the inside surface of the machined bearing housing of the crankcase.

It ain't going to come out without splitting the cases.

well I hope like hell It can be the clutch or something else then.. there's absolutely no point in me splitting the cases on an engine thats going to be replaced in a matter of weeks..... "ride and pray" might be my only option

[speeding_ant]

Wasn't you shooting up Ghuznee street last night was it?

If it was, your carbs need a damn good cleaning

[bogan]

well I hope like hell It can be the clutch or something else then.. there's absolutely no point in me splitting the cases on an engine thats going to be replaced in a matter of weeks..... "ride and pray" might be my only option

I'd caution against that, things like a bearing cage splitting apart has the potential to do a lot of damage to the gearbox, and cause a rear wheel lock. Not worth the risk unless you can identify the problem as not having that potential imo.

[the bear zxr]

Wasn't you shooting up Ghuznee street last night was it?

If it was, your carbs need a damn good cleaning

not me!!!! last night the bike got a quick loom tidy (just re-taped the central snake)

[jasonu]

because it clearly has nothing to do with the engine itself.. only the gearbox... whether the engine is running or not makes no difference to what parts move when the bike is rolling

So if the engine is not running ie switched off how does the gearbox make any noise at all?