Transmission clunking

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Transmission clunking

This is a discussion on Transmission clunking within the ZR-7 Maintenance forums, part of the Kawasaki ZR-7 category; On my 2001 ZR7S the transmission makes a clunking sound when in neutral. With the chain off and trying to turn the engine sprocket by ...

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Thread: Transmission clunking

  1. #1
    Up-And Comer Ratchet101's Avatar
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    Transmission clunking

    On my 2001 ZR7S the transmission makes a clunking sound when in neutral. With the chain off and trying to turn the engine sprocket by hand, the shaft does not turn easily. It will turn for about half a revolution easily then hit resistance and with force will turn the rest of the way making a clunking noise. When I drained the oil no metal chunks were found.

  2. #2
    Supreme Being rcannon409's Avatar
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    Thats an older bike, how about it being a chain issue?
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  3. #3
    Up-And Comer Ratchet101's Avatar
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    The noise and resistance happens with the chain off (or on).

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  5. #4
    Supreme Being Vic.Thing's Avatar
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    Your post is a little confusing. Are you saying that you're looking into this because your bike running, in neutral, makes a clunking sound? Or are you saying that you only experience this with manually turning the engine sprocket? If you have your chain on and spin the rear wheel in neutral, do you experience the same sensation of drag?

    My throw the cards in the air guess is you have a bad bearing(s) somewhere.

    It could also be a bent or worn shift fork allowing the gear to partially engage the gear it's next to.

  6. #5
    Up-And Comer Ratchet101's Avatar
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    Didn't mean for any confusion. This what happens when the bike is not running and in neutral. It happens (not running) when you push the bike, set it on its center stand and spin the wheel and also with the chain removed and the sprocket is being spun.
    I agree, it sounds like a bad bearing or a worn or bent shift fork.

    Now, is there a fix for this without removing the engine or does the engine have to come out to fix the bearing?

    I realize the engine has to be removed from the frame to fix the shift fork.

  7. #6
    Supreme Being Vic.Thing's Avatar
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    So the bike doesn't make any sounds when running? No clunking or clanking? In neutral, no issues or sounds? Up/down shifts through all gears no problems? Stays in gear all gears, no problem, under heavy acceleration and ALL conditions? You only experience this when the bikes off and you are manually turning it in neutral? Any clutch issues?

    When did you first notice this? Is it different than what you've experienced before?

    Is it possible for you to record a video so we can see and hear what you're talking about?

    What happens if you disengage the clutch? (use something like double sided velcro to strap the lever). Whens the last time you adjusted/checked your clutch lever free play? Clutch cable inspection/lube?

    I don't own a ZR7 so I'm not sure about servicing the bearings without splitting the case. I downloaded a service manual, I spent a few minutes looking it does not appear to me the transmission bearings are servicable without splitting, but I am not certain of this at all and only had a couple minutes to look at it. It looks like a couple bearings might be, but it didn't appear the transmissions were. I'm sure someone here can answer these questions with 100% certainty.

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    Up-And Comer Ratchet101's Avatar
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    Thanks for the suggestions. It appears I will have to remove the engine to replace the bearing(s) as well as the shift forks if needed. I will keep this forum informed of what I discover. Just got to get motivated to yank the motor.

  9. #8
    Up-And Comer Ratchet101's Avatar
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    To update everyone on what the transmission clunking noise was I pulled the engine and split the cases. First gear was broken into five
    plus pieces. A new transmission is being installed and the cases are being put back together.
    Attached Images Attached Images
    Last edited by Ratchet101; 01-04-17 at 01:19 PM.

  10. #9
    Supreme Being Vic.Thing's Avatar
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    LOL well I was sort of right about the partially engaging thing...

    Any idea what happened? Have you formed any opinions of the gear breaking? Looks like something got wedged between the gears and crushed it inward, where the teeth are broken.

  11. #10
    Up-And Comer Ratchet101's Avatar
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    Quote Originally Posted by Vic.Thing View Post
    LOL well I was sort of right about the partially engaging thing...

    Any idea what happened? Have you formed any opinions of the gear breaking? Looks like something got wedged between the gears and crushed it inward, where the teeth are broken.
    Actually that's the way I got the bike. So, no I really do not know what could have happened. Maybe the gear was structurally weak to begin with and at one point broke. The other gears are in decent shape except for a few nicks from the broken gear bits that were floating around.

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    Up-And Comer anilv's Avatar
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    Bloody hell! You have to offer a sacrifice to your guardian angel, that could have gone bad very fast.....

    You must be living right!

    Cheers!

  13. #12
    Supreme Being carryall's Avatar
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    Unless that gear was cracked, or poorly machined from the factory, I'd say abuse was it's cause. Dropping the clutch, (burnouts, wheelies, etc.) would/do put ALOT of strain on the gear, chain and the counter-sprocket, and I believe the first gear sprocket would be the weak point between the 3. Just an educated guess.
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  14. #13
    Supreme Being Vic.Thing's Avatar
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    Maybe a bump in run? I know that can foul up a transmission pretty well.

  15. #14
    Site Elder motocopter's Avatar
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    That is pretty spectacular to find! Looks like you confidently isolated the trouble correctly. Nice work.

    I've had one dog of a slider gear snap off on a CB-400F back in the day. Made a loud clack sound when it happened, so I knew something went wrong. It occurred during a down shift.
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  16. #15
    Up-And Comer Ratchet101's Avatar
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    Actually, this is my first attempt at splitting the cases on a motorcycle. It's been a real learning experience for me and I am glad that it has gone well up to this point. I'm anxious to get the bike up and running as there are several other bikes waiting to get worked on.
    motocopter likes this.

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