Question about 1994 kawasaki Zephyr 1100

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Need to change second gear in zephyr 1100. whats best way to go about it.

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  • Marvin
    Marvin Jul 15, 2010

    1st step buy a factory repair manual.

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You are talking major surgery here. I don't recommend this as a project for the home mechanic. If you insist on doing it yourself, go to the website below to see a parts diagram of your engine. This site is an excellent source for parts. www.babbittsonline.com/pages/parts/viewbybrand/default.aspx

You may be able to download a free service manual at the following site, they have over 3000 free manuals online. www.babbittsonline.com/pages/parts/viewbybrand/default.aspx

The process is to drain the oil, remove the engine, clean the gearbox free of dirt, flip the engine upside down, then split the top and bottom crankcase halves. This will give you access to the gears and shift forks. ALWAYS replace gears in sets. Replace the broken gear and the gear it meshes with. If you don't, you will get the joy of doing the repair job twice.

Posted on Jul 16, 2010

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  • Contributor
  • 6 Answers

You will need to replace three gear cogs and it is a total engine strip which may not be economical. I have a complete pictorial guide plus the part numbers needed listed on www.redzed.proboards.com from when Rebuild my 1992 Zephyr 1100 gearbox.

Posted on Nov 12, 2014

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Posted on Jan 02, 2017

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p.s. Seller:s.gif s.gifchaplinkawasaki

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