[ninja167]

Hey guy's and Gals , just a quick heads up to all with 07 /08 zed's ,check out your gear selectors you will need to remove your foot peg .Mine is the 3rd one in the area to have seized , apparently not enough grease was applied from the factory . so if your gears are feeling abit notchy , have a look or take it back to the dealer .:attn:
:alcy:

 

[BB-z1000]

hmmm,

i've noticed a little notchiness which i mistook for an oil selection problem or something that would go away after break in.

what must you do to remedy? remove the gear selector foot peg? or the entire rearset?

must you get into the clutch plate area to regrease?

cheers

 

[mr.jones]

hmmm,

i've noticed a little notchiness which i mistook for an oil selection problem or something that would go away after break in.

what must you do to remedy? remove the gear selector foot peg? or the entire rearset?

must you get into the clutch plate area to regrease?

cheers

+1 Good lookin' out!

 

[RoninZ1K07]

Any chance you can post some pictures of exactly what we should be looking at or what we should use to fix it?? I have a shop manual, maybe someone knows from looking at that?? Just wan tto know what your talkign about exactly cuz it soudns almost recall worthy. Also think mine might have this problem a little bit. THnx for posting this up. First I ever heard about it!!!:wtf:

 

[bmpopp]

Hey guy's and Gals , just a quick heads up to all with 07 /08 zed's ,check out your gear selectors you will need to remove your foot peg .Mine is the 3rd one in the area to have seized , apparently not enough grease was applied from the factory . so if your gears are feeling abit notchy , have a look or take it back to the dealer .:attn:
:alcy:

That's funny this has come up, because I thought something was odd when I took mine apart. I had low side a while back and broke the shifter lever and actuator rod. When I took it apart, it seemed almost dry. I packed the new one full of automotive axle grease (the red Valvoline stuff). It's been smooth as silk for 6 months with no signs of leakage.

 

[eidian]

Any chance you can post some pictures of exactly what we should be looking at or what we should use to fix it?? I have a shop manual, maybe someone knows from looking at that?? Just wan tto know what your talkign about exactly cuz it soudns almost recall worthy. Also think mine might have this problem a little bit. THnx for posting this up. First I ever heard about it!!!:wtf:

+1 I'm a mechanical moron and pics would really help out. Thanks.

 

[Guest]

yes, pictures please!

 

[bmpopp]

- Slide the Foot-Peg mount, with the outside oil seal in place, through the Shifter Lever.
- Pack the inside of the Shifter Lever full of grease.
- Put the other (inside) oil seal in place, and mount assembly onto bike.
- This will also give you a chance to set the shift rod to make the toe position more to your liking.

 

[mr.jones]

BMPOPP ,"big up" to ya! :righton: I'm a gonna fixit right now!

 

[Guest]

Thanks bmpopp! I too am going to spend some of my precious Sat. checking/fixing this, and it will be a nice bonus to lower the shifter a bit too!

Thanks for the picture, but the background showed up black because it was in bitmap format, so I went ahead and converted it to jpeg so no one would be confused if they see a black background like me. Thanks again!

-Daniel

Here is your pic with a white background:
View attachment 33775

 

[RoninZ1K07]

+1 NEED STICKY ON THIS!!! :dance:

 

[ninja167]

Thanks for the pic's guy's it's a great help, i didnt have any. i just walked in when my bike was in for a service , he had it pulled apart and said " no probs at all , i'll replace it all under waranty".so hope this has been a help to everyone.
cheers:alcy:

 

[mr.jones]

Finished greasin' the peg up! Here are some things to watch out for: 1. the red Locktite on the bolt that holds the footrests makes it tough getting it apart, be careful not to strip it. 2. You'll have to take off the whole assembly before you can get to the seals - start at the bolt that holds the shift linkage on. This bolt is located in front of part no 39110 on the diagram and connects it to the bike. After that is off then the two hex bolts that hold on the rearsets (not pictured) will get the whole shebang off. 3. I didn't notice a seal that was in between a plate that is on the rearsets and the lever (part no 13236a). When I packed grease inside the lever hole and the seal (in between the footrest and the lever) the side by the rearset had an indentation on the plate that took the shape of a seal, but didn't have seal! Maybe I remember wrong (I didn't look at the diagram again while I was doing the work and I just noticed this now)! So maybe that's why these things get notchy. When I was trying to get the footrest assembly out from inside the lever, a ton of rust came out. With some muscle, twisting and WD-40 it came loose so it's obvious where the lever seizes. I'm not going to take it off again to check about the other seal but if it starts to shift poorly again I'll know why and get the other seal.

 

[Guest]

Yeah, that lucite bolt is a pain. Use a size 6 allen wrench on it and put a pipe on the allen for leverage. Also instructions to remove the shifter are on page 359 of the '07-08 Service Manual. I have also attached an image of the page in the manual. I saw what it would be like if I moved the shift rod, but the change was a little too dramatic for me. I didn't quite understand where you found rust mr. jones because I didn't see any, but then again my bike is only 1500 miles old. Hopefully this helps the bike, cause I've been hearing a strange clicking in that exact area, but I think it is something in the actual transmission. The sound happens around 4,000 rpms when I'm in about second or third gear, and it sounds like a clucking of the tongue if that makes sense, any thoughts?? Take care!

-Daniel

View attachment 33776

 

[BB-z1000]

man this website is great! :woot: :woot:

very simple to fix / do.. im a novice but instructions were easy to follow. :woot:

this needs to be a STICKY!!!

i'd recommend everyone take the time to do this..

mine didn't have any rust, but it was BONE DRY! after filling with castrol grease the action felt much smoother.. could save much complication later down the line with siezing.

thanks to everyone for posting and identifying issue! :righton::righton:

i've attached some pics, they aren't a walk through, just some pics for better understanding.

And by the way.. best piece of advice i can give any novice mechanic ish person. Buy very good quality tool sets!!!

i used to think a rachet was a rachet but there is a massive difference between a $10 set from china (that will strip and destroy your nut heads) and a good quality $50 Stanley set - the red locktight was easy to take off first try with a quality tool.

i've also attached a pic of the rachet set i use for almost everything.

by the way i used blue toctite of the thread that once had red on it.

peace

 

[eidian]

Thank you to everyone!

You guys are all awesome! I'm going to try to do it tomorrow with my laptop in the garage (high speed wireless at home is the shizzle!)--if not tomorrow, then definitely Monday evening. Like I said before, I'm a mechanical moron but all of the pics and diagrams have made this a job that even I can do.

 

[mr.jones]

Daniel-son thanks for the manual post. I'm gonna line up the dot to the slot! (Didn't ride it yet and I think you may have saved me from shift disaster :ithank I think that the rust was from a couple of trips through the rain and 11,400 miles on the clock. Did anyone notice if there was 2 seals as per the parts diagram? +1 on the proper tools BBz1000! I ain't got 'em and I need 'em! :smashfrea

 

[Guest]

Daniel-son thanks for the manual post. I'm gonna line up the dot to the slot! (Didn't ride it yet and I think you may have saved me from shift disaster :ithank

No problem, I recently downloaded the copy of the 07-08 manual and thought I would see if it helped at all.

Did anyone notice if there was 2 seals as per the parts diagram?

I had 2 seals. I'm thinkin without 2 seals your lever will go dry again real soon.

Take care all! About this being a sticky, it's probably better suited in the maintenance section :2cents:

-Daniel

 

[BB-z1000]

Mine definitely had 2 seals also.

Rode to work this morning - what a difference! :sweat:

Felt sooo much smoother.! :bling:

 

[[email protected]]

Great update guys!! Mine wasn't dry, it was the sahara desert. So took the parts apart and greased it all up.

Has anyone thought about the other lube points? i.e. The rear break lever? Steering head? Rear shock linkage?

Any thoughts?