New Voyager New Project ugh.

[ivel_86]

Let the fun begin. I am going to replace the water pump, amp, igniter, possibly valve cover gasket. The gasket is leaking decently and there was one I the trunk of the bike when I got it so I might as well put it on. Gonna change the plugs since I am this deep as well. Carl Leo is shipping the pump amp igniter and cable tomorrow I hope. ANyways I already poked a hole in the lower radiator hose because I didn't know that I should have removed the lower cowl so I could loosen the hose easier. Either way I got the water pump out.

[sheiserman]

Looks like fun....

I did the valve cover on mine last winter. Carl asked if I removed the carbs, which I didn't. He said that makes it easier. I was able to split the valve cover into the two halves to get it out, but I had to roll the engine down to get it back together. I put in new rubber seals under the cover bolts too. Seems like there were 8 of those. Careful removing the cover, there are some rubber pieces that may fall into the engine. I had the manual by my side too. Fear mandated the manual.

Good luck.

[Lucasind]

Let the fun begin indeed ! I noticed ya mentioned that Carl is sending you a igniter ?
After removing the fake tank,you in fact DID find the igniter to have the (1179) last four digits ? (bad)

[trikebldr]

Wow! A naked XII!!! I wish my 1300's fairings would come apart like that! I guess Kawasaki learned all of their lessons on the 1300s before making the XII's. Sweet!

[ivel_86]

Yea bad igniter, so Carl is sending a new one.

Any more advice about the valve cover? What rubber can fall into it? I don't plan on and don't want to pull the motor. You mentioned rolling the motor forward? You mean you dropped the engine down? Or loosened and lifted it?

[triton28]

Ivel;
in the service manual, Section 4, page 8, the 4 rubber dampers which can fall into the cam chain tunnel are shown.
https://www.amervoyassoc.org/zg1200manuals.php" onclick="window.open(this.href);return false; has all the info you could want.
Dave

[ivel_86]

Well those are the worst pictures HA. I will have to see still haven't sold myself on the idea of doing it. But on the same note I sorta want to and just be done with it.

[Me Again]

Wow! A naked XII!!! I wish my 1300's fairings would come apart like that! I guess Kawasaki learned all of their lessons on the 1300s before making the XII's. Sweet!

I have to admit I am a BIG fan of the 1300. I feel as though if Kawasaki had done the subframe thing to the fairing ,did the gas tank/battery swap (fake tank) thing and put in a higher gear the 1300 would be the ultimate touring bike.

[sheiserman]

Yea bad igniter, so Carl is sending a new one.

Any more advice about the valve cover? What rubber can fall into it? I don't plan on and don't want to pull the motor. You mentioned rolling the motor forward? You mean you dropped the engine down? Or loosened and lifted it?

I've only ever done the one valve cover, so I may not be the best guy to be giving advice on this. But, I got it done and it doesn't leak.

The way I went about removing the cover/s, I got lucky with the rubber dampers. I lost my religion when I pulled the two cover halves off and seen only three dampers. Fortunately, one damper was stuck to the inside of the valve cover. Best tip I could give there is lift each half as high as you can and pull it straight out as smoothly as possible. For all I know, it really isn't too big of a deal for most people.

As far as putting it back in, I decided I had to lower the engine to keep from fighting the gasket. I loosened the rear mount and removed the front two, and just rolled it down (as far as I know, I didn't damage anything else doing this). I had to use a scissor jack under the engine because my floor jack was too tall and didn't let it roll down far enough. I'd wager lowering the engine would have been beneficial when removing the cover too, but I didn't think of it at the time.

That's how I did it.

[ivel_86]

Well got the exhaust off, radiator and other such stuffs. Talked to Carl, gonna pull the motor. Prolly gonna break a bunch of stuff! UGH HAHA I love tinkering though. Luckily the weather is supposed to turn sour so I aint hurting to bad. Hoping and praying I don't break anything to awfully expensive.



Ya know its getting serious when I start bagging thee stuff.

[ivel_86]

So when pulling the engine, do I unbolt the housing for the drive shaft or do I leave that on and it just slides out? Also the carbs should I leave them on the engine and disconnect them from the air box, or should I disconnect them from engine and leave them on the bike?

[ivel_86]

Any help on the above question?

[Gator Mike]

When I took mine out I removed the carbs. I marked all harness connectors and took a lot of pictures which helped greatly in installation. When you remove the drive shaft be aware there is a pin you need to depress on the engine side that is spring loaded. As you slide back the driveshaft catch the pin or the spring will shoot it out like a cannon. Spent half an hour looking for it before I found it on my shop floor. Take your time and it should go well. Some time when you talk to Carl again ask him how long it takes him to take an engine out. It will absolutely scare you. Good luck...........Gator Mike

[ivel_86]

Yea I talked to him a smidge about it. He said it takes him 45 MIN!!!!!!!! Holy crap. So do I need to remove the rear tire like the book says? And also the final drive as well?

[ivel_86]

Alrighty. It is out. I am going to pressure was it at work and than flush the coolant. Then let it think about its mistakes and in the end whip it back together.

SO Carl Leo is a stand up guy. Serisouly helping me already a hundred times, plus a veteran! Got his package today.










SO also I now know why Carl said to have someone help you, aside from the fact I snapped two wires idiot me cause I didn't see them pulling, I also did this. Seriously I am dumb sometimes I just don't have people nerby that can help.

[sheiserman]

I forgot about having to remove the frame section just to roll the engine down like I did.

I'm not sure how much more it would have taken for me to have just removed the engine, but the valve cover job looks a lot less threatening the way you are doing it.

[trikebldr]

Wow! A naked XII!!! I wish my 1300's fairings would come apart like that! I guess Kawasaki learned all of their lessons on the 1300s before making the XII's. Sweet!

I have to admit I am a BIG fan of the 1300. I feel as though if Kawasaki had done the subframe thing to the fairing ,did the gas tank/battery swap (fake tank) thing and put in a higher gear the 1300 would be the ultimate touring bike.

Or, maybe just hang another couple of cylinders on the ends of the XII's engine block! That's an awfully narrow looking engine sitting on that garage floor! Just think! That would have made an 1800cc inline six engine! AWESOME! Prolly would have come close to putting out 150 to 160hp!

[ivel_86]

well washed the engine up today, gonna paint it and reinstall it. Not looking for a lot out of the paint except a little protection as it has a little service rust on it.






after

[cushman eagle]

Now would certainly be a good time to change the coolant manifold and water pump O-rings and seal.

[ivel_86]

I am putting a new used waterpump into the bike. Why would I need to change the manifold? Or do you mean just the orings on the manifold.?