whats up guys ive actually have a quick question about my ninja (i kno its hondatech but all the other forums suck ***** compared to this one) , my problem is the start just spinns freely not grabbing the flywheel and turning over the motor ive narrowed it down to the starter clutch, although a pita taking the motor out for this , my quesions are
anyone have any experience doing this and can lend sum advice
-- also where is the best place to buy the rebuild kit for the starter clutch (oem or sum online site ?)

any and all help is always greatly appreciated
1994 zx9r b1
heres a thread i made for a diff site earlier
hey whats up guy names jd recently picked up my first bike off of craigslist 94 zx9r for a grand knowing it didnt start PO said from sitting over winter or such (turned over sounded fine figured what the hell). after screwin around with the carbs and reading a bunch of pplz post i got it fired up and runnning albeit not smoothly , the PO had done the worst possible job taken care of this one lol . :thumbdown trying to start the bike i was getting the clunking grinding noise randomly then more often as i was doing random things preppingit to ride then one time the clunk noise was louder than normal almost like the gear jammed now the starter spinns with out turning over the motor. i took the side of the tranny of and its like the shaft isnt spinning enough to make the flywheel turn over, which led me to beleive the casses need to be split to replace the starter clutch or am i wrong in thinking this

(PICS)
heres the bike i didnt like the exhaust at all so that was first to go




here u see it wasnt the most thought out exhaust thefingerbanghead

off with that crap ::clap on with the new donated by a friend of our shop richie of middlesex petroluem good dude alway helps with what we need for shop supplies
heres my buddy doing another favor welding it up to the stock headers for me

the pipe wasnt an exact fit but hey if its free its for me lol theproblem was the pipe was to close to the foot peg
i just took a torch heated it up cherry red and slowly bent it down and out away from the frame and peg (pic will b uploded soon)
then i decided to tackle the patch job fairing work the POS PO did


at the same time i removed the tank and decided to teach myself how carbs worked


this is when i realized i was in trouble after getting it running the starter decided to not work any more
ive now noticed the oil had a decent ammount of gas mixed in :headscratch
i figured screw it this bike needs to be thuroughly looked over and i figured its worth a shot i hope you guys have any help to throw my way andy and all help is greatly appreciated
fancy pic before i ri[ its heart out

all out pretty easy to take out with a few beers and an extra hand anyone can google/youtube how to do it lol



it looks like the PO used glue or sumin on the vavle cover

heres better shot of it
looks like a plug wire was glued as well lol

Also i noticed what looks like a oil leak i cant tell if its been fixed and its residue or a problem either way im thinking headgasket replacement for peace of mind any thoughts?

also another sign of lack of maintence the chain cover was caked in rust metal




i know i wrote alot hope u guys can help make this thread one that is actually a full build and seen to the end

if the other pics didnt help heres sum of the shops other toys

 

lol 180 ppl and no thoughts lol well anyway heres an update



i have everything apart down to where the problem in the shaft off the alternator that clutch sort of thing when i lwly turn it it binds up and jams fully at sum points, so i imagine when the starter tryed spinning it it just wasnt engaging. it would cause the bike to make a wicked loud grinding kindof clunking noise


im pointing at the bearing or whatever holds the starter gear it self in how is this removed??


this bearing seems to be no good or no ? compared to the on pic before^^^^^


here u can see the clutch assembly thats connected to the alternator this seems to be binding up and has to be whats causing the starter grabbing / clunking noise how any clue on what this part is

 

lol wow not even a thumbs up for all the pictures lol im gonna keep posting just on principle now considering half the car threads just die off and whatnot

hey guys heres an update so today i took the headers off and over to my dads shop to clean up the welds on the now temporary yoshi (temp due to jowek70 @ zxforums 4 hooking it up with a nice slip on )
check out theese welders lol enough juice to weld a train to its tracks lol :blob

doing my buddys(&BOSS)'s CBR1000RR engine mount cracked and we had to weld the aluminum alloy motor mount i reccomened my old man for the job anyday


i also witnessed a guy who always ****ed with me when doing car projects on the street before i started at the shop smash his truck into the lady in front of him lol all because he was starring at my civic of all things haha:rotflmao:rotflmao:crackup:mfclap


heres my other pride and joy of motoring this one actually starts so i prefer it at the moment but the 9r is a close second


back to the bike i weent in and took pics of sumin i completely forgot about the water pump has a knick taken out of the part that it conects 2 to make it spin. (i found a small peice in the oil pick up screen dunno if it can be seen)



:banghead:banghead:banghead

this area where the ditributor / ign area has this been changed or does factory meean oem part ?? also look at the POSPO jerry rigging job of using caulk as his new gaskets everywhere lol



here is my organized chaos lol label evrything and put it on tray as it comes off and alll bolts go back in the holes they came from to help easeup the reinstalling , if i didnt have to work on customer cars and also pump gas all at once i would of gotten more done but gutta get the cash to fund the projects first am i right guys??




more gun stuff :M16 :evil

also just picked up a helmet offline z1r jackal helmet hope u guys enjjoy all the pics

 

digging this, between the helmet and the guns awesome.. the bike

good for you for fixing it!! what an a$$clown the last owner was..

keep it up, big project there

 

Thanks man i appreciate it actually bought this biike to learn how to ride lol now im learning how to rebuild it instead the last owner had to of had a rice complex with his bike i didnt think it was possible lol

as far as the problem goes ive narrowed it down to the generator shaft one way clutch initialy it would grabb and hold and cause the crazy clunking grinding noise

trying to figure out best possible solution should have more pics up today

 

looks like a fuggin headache, keep up the good work man, the best way to learn is to jump into it head first

 

yeah its a bit of a bitch but figured out the problem and hopefully it just needed this clutch and double check everything gets tourqed down and gaskets that are the right kinds

as of now ive gut it all broken down im still double checking what i exactly neeed to order and i cleaned the **** out of it the last two days jus being bored lol

 

heres an update for everyone hopefully ppl can throw some thoughts out any input is helpful

so i started the day off right witha smoke a a coffee lol






after a busy week gf problems and the holiday weekend it really slowed me down but i got a bit more done and figured to share..
i got the generator shaft removed from the case a little tricky since the pins and washer come off the internal part then unbolt from the outside part
of the case where the alternator would go


then everything easily pulls right out ,,,
after i removed the one way clutch assembly i noticed its gear teeth seemed pretty worn ? or maybe this is intentional im not quite sure and figured you guys could help me out please:smile:headscratch:smile





Also the shaft that the clutch slid back and forth on had slight marks on the teeth but only in one small spot i tried getting a photo but it may be hard too see






few of the boss' toys and a shop shot lol a bit of a mess nbd though




heres the whole generator shaft together outside the case THE PROBLEM is someting to do with this one way clutch anyone kno how it operates ?




had the motor on a tire and carboard for the first day or two removing stuff but once the caes were opened it had to be in kept up and out of the way so i made myself a little operating table secured it down with a ratchet strap to avoid any accident when im not there god forbid (prior experience when building my civic) also put it up there and started cleaning the grime off and old gaskets








removed the valve cover after cleaning and noticed the new cover gasket and the internals seem really new






POSSIBLE PROBLEM

i noticed today a bearing journal is in different compared toall the others can this cause major problems? what should i do about it

 

status update


currently taking specs of the bearings for the crank and trying to figure the correct bearings neeed

hope u could help when i was going to order some parts and gaskets i am a little confused whati need to kno in order to get the correct ones heres a fiche of the bearing and it says cde or fgh ????? anyone ever order these parts before how do i go about ordering the correct ones/? as always any help is greatly appreciated

http://www.bikebandit.com/houseofmot...149969sch61636

heres sum pics of the bad ones



also heres the link that isnt working a screen shot i did in paint to giveu an idea
\
\



on another forum someone gave me this great link
http://www.ronayers.com/Fiche/TypeID...oup/Crankshaft
http://postimage.org/image/r413ay71t/

 

bump this got all the parts this week 400 later off bike bandit i
will hopefully have motor in bike by sunday

 

I just split the case halves on my gsxr. not the easiest thing in the world, but with the service manual and an engine stand, it's doable.

Had to fab my own brackets for the stand.

Good luck.

 

tthanks for the advice man i luckily have my bddys shop and a few ways of jacking the bike up .//././. use a ratchet start around in good spots and use our lifst like a crane lol help to kno the bike cant fall over oon you ,.,., i had to fab up my own socket for the bolt on the clucth plate so i like the creativity of doing ur own stand

\


i also decided id give welding a shot and i think i did alright the thing worked and didnt dbreak albeit my weld look like a rape scene

 

so i was looking at my timing advancer and noticed it had sum play in it even bolted tightly it wiglled slightly so of course i unbolted it for a closer look and found the old on was what look like hammered into the crank and all screwed up ,.,., ive already went and bought a new pin im curious though how it is installed the haynes doesnt help and google wasnt much better anyone have any experience installing this pin?



here u can see where the old pin was


here u can see the timing advancer has a nick in it now



.,.,.,..,.,.,.,.,.,.,
.,.,.,.,.,.,.,..,,.,.

i have received all my parts need to attemppt the final build,.,.,. i went ahead got alll new gasket throughout the motor and and bearings and seals the had even the slightes wrong feel about them ,.,.,.,., bikebandit . co m is very good and very fast will be using them quite often from now on .

the biggest thing with rebuilding this and reinstalling the case was prepping the surfaces to mate up and using very little a silicone gasket to help make a nice seal ., i took not of where the forks were on removal so when i re installed the case the shifter forks went right back into the correct spots,
also i pre lube everything and make sure theres no dirt residue we have a wash tank with zep cleaner stuff is great at the nasty **** the buins up on the outside of the case and the heavy oil at the bottom of the pan






heres the SOB that caused all the headaches


heres the cases in place anyone with a keen eye may notice the gasket missing lol yeah i figured it out to about 1 minute after the pic lol :bugerit




and here is some random photos ive taken to switch it up on u




(nextphoto was taken from @freshonstanceandofffset face book page)
back to the bike :lol: :D

this was a first for me having to do battery acid and charge its very easy though i can only imagin what it was like for ppl back in the day when it was routine


here i decided to just get the generator and starter in before installing it in the bike

my last pic before i got it in the bike all alon so snapping pics was not an option but i will post them first thing tonight


i had started around 7 pm left the shop at about 2 am =0 :evil: :evil: #dedicated lol

 

so i i couldnt realy take photos cuz iwas going solo late night after the shop closed and i was determined to gett this motor bike in its frame i wouldnt of slept if i didnt have it in lol u guys kjnow how it goes ... the photos all like like the same but the one outside is right after it being re installed ,., the next two are after i finsihed most of the wires and exhaust (jowek i still wanna grab that carbon can just had to fund the parts train first lol) also re installed the chain have to do a little rebuild of the clutch piston i accidently pulled the clutch when it was removed so i bought new seals for it





also i had to stay busy for the time it took for the parts to get from wherever to me so i decided what the hell wire tuck and battery in the trunk my civic lol




and my teachers wanted me to take ritalin in elemantary school :thefinger:thefinger:thefinger:crazyloco:crazyloco

 

so ive come across a bit of a problem the spring pin or dowel pin on the end of the crank has busted off .,., i have the ability to drill the old hole out and have areplacement pin already to go into the bike but im not sure / inexperienced in installing this type of part before i hope someone could maybe lend some knowledge




here u can see where the old pin was


here u can see the timing advancer has a nick in it now

 

anyone wanna share thoughts i dont mind lol 1500 + views im in the process of thinking of a new color any thoughts?



update .,.,., i am still curently stuck on the spring pin install im going to get it though to determined not to ,.,.,, also waiting on a generator shain tensioner has a lil crack in it and was hard to get back into place like the spring inside imanagaed to fix it but its in the bike as a temporary peice just so i know where the parts goes


anyone have a good site where i can fins this tensioner ??

 

update

so i went through several pins before thinking of two ideas well one new idea the other was brought to light on here in previous post ,., my first idea is i went and bought long pins with hopes the angle it goes in at wont be affected as compared to the smaller pin, if it works i will use a cutting wheel to cut to proper length




the other idea weve discussed is a final resort and will eventually look similar to my little sketch ive drawn

 

i applaud your dedication to this bike man, good job on the rebuild and the play by play is educational to us that arent too keen on the older models. i wouldve given up on this bike weeks ago given all of the issues that you are running into, i really wish i could offer more advice on your project

 

update ,., well besides for the god damn pin problem lol ive decided i will get everything else buttoned up as far as wiring (what was left) , radiator ,headers, a clamp i had broke on removal i had welded up and cleaned up nice ., going to go as far as possible tonight , will take many pictures as always and also hopefully install this pin and then i will be on to installing the chain tensioner and, that will allow for me to install the clutch plates and stuff and all the covers and i will b good2go sort of lol

does any one have any experience with the unniversal spark plug wire kits ? im not quite sure how i go about wiring these up i figure it has to of been done previously ?


heres the repaired header clamp


#-o

TO DO LIST
~repair clutch piston seal (i pressed the clutch with it removed ,.,. yeah dont do that )

~ install chain cover

~install water pump(still have to fix that shaft problem )

~ remove and reinstall new chain tensioner

~figure out spark polug wire situation

~install roll pin "spring pin" and timing advancer (still concerned about it being +2)

~install radiator and fix lower mounting brackets (seems to have damage from when the bike was layed down by POS PO )

~theres some wiring issues also just need clean up connections and tape certain spots. (alson have the ground wire coming off the harness and a thicker wire i forget where it goes it seem like it connects to the frame/motor sumwhere i wil get a photo later tonight)

~ while i am there make another to do list LOL :lol:

 

hey man thanks i hope i can help ppl out anyway possible ,.,. i would have also givin up but this version bike is only comparable to say if i could get a nsx lol just sumin ive wanted since i was a kid ,, besides for the ugly blue paint (soon to be vinyl wrapped wit a cool idea ive been working on )
,.,. any thoughts r helpful u may think of sumin i overlook and hey id rather someone give an idea and it not work than nothing at all u kno what i mean

 

soo appernetly its possible to swap over to coil packs ?? instead of the spark plugs and ignitor coils

 

CSo i have a 94 9r and i was tryin to start it one day it mad a clunking noise then the starter just started spinning freely ,., i went about splitting the cases an replace every peice i could tell was broken i thought i was as **** about it as possible ,., jus got everything back in and before puttin the clutch cover on and stuff i gave it a quick turn over(or attempted to at least) and the starter is still just spininng im bafffled /:

-- bike didnt have fluids other than assembly oil on all parts
-- i tried reversing Polarity on the starter motor sounds anout the same
---does the starterr one way clutch need the motor full of oil to operate properly ?
-- is it a starter motor problem ??
---- anyone have a properly funtioning motor for sale ;(

 

bump ttt hope sumone can lend sum thoughts,.,.,..,., have it back together but it seems like the clutch hub/ flywheel doesnt wannna rotate enough when the starter is turning the chain assembly

 

After all that BS the 9'r does not fire up for you?
I would try to bump start it. Find a nice hill or a few willing friends
and let the clutch fly in 2nd gear.

 

it has the ability to bump start it i tried tonight it had no gas but i could hear the motor turnover thru the exhaust .,., my brain is boggled lol im stuck to beleive it has something to do with the clutch or clutch release pistonor sumin in that assembly


if i attempt to start it the black gear hub trys to turn sliightly but not alot ,.,. the inner chain spins fine ,., its why i think its clutch related