another starter chain thread

gosupes

gosupes

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I'm sure someone has looked this up this before and knows this by heart. I noticed some strange noise when cranking her over today. I pulled the clutch cover off and found the start chain has some links that are binding and a chipped tooth on the starter gear. I seem to remember some of the parts have been upgraded or superceded. So far I have the chain, number 92057-1292, the crank sprocket number 12046-1067 and the starter sprocket number 12046-1068 Not sure about this last number, just did a search on the word sprocket and the diagram looked right). These are ZL numbers, not sure what other years cross reference. Anyone done this recently? Any insight would be helpful. The good news is that the tensioner hasn't broken like some of the others have experienced.
 
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gosupes said:
I'm sure someone has looked this up this before and knows this by heart. I noticed some strange noise when cranking her over today. I pulled the clutch cover off and found the start chain has some links that are binding and a chipped tooth on the starter gear. I seem to remember some of the parts have been upgraded or superceded. So far I have the chain, number 92057-1292, the crank sprocket number 12046-1067 and the starter sprocket number 12046-1068 Not sure about this last number, just did a search on the word sprocket and the diagram looked right). These are ZL numbers, not sure what other years cross reference. Anyone done this recently? Any insight would be helpful. The good news is that the tensioner hasn't broken like some of the others have experienced.
Click to expand...

I have a similar noise problem, as you, within that clutch area. Heretofore, I've been relying upon Power Edge's and Babbit's Online websites for up-to-date parts and numbers clarification. Both these sources appear to be very close in their individual pricing; I haven't found a wide variance in cost; maybe a buck or two either way. Another member is helping to clarify which year and model upgrades to use for the problems I'm having. When received, I'll post those part numbers for you, if still needed, just let out a holler. Hope this helps you.
 
I think the zzr upgrade is for the starter clutch. The cam chain guide and tensioner are concours upgrades. Not sure I've heard of an upgrade for the starter chain, tensioner or sprocket. I've only seen the mod of an existing starter chain tensioner. Could be wrong though. Later.
 
Jarney said:
I think the zzr upgrade is for the starter clutch. The cam chain guide and tensioner are concours upgrades. Not sure I've heard of an upgrade for the starter chain, tensioner or sprocket. I've only seen the mod of an existing starter chain tensioner. Could be wrong though. Later.
Click to expand...

I believe someone posted about the starter clutch from the ZRX being a better design and bolting right in to the zl.
 
Maybe that was it, I've read so many various upgrades, it's hard to remember which is which.....Later.
 
That's what I read, now that you mention it. Parts ordered. What's another c-note? She's been pretty good to me this year so dropping another hundred is not too much to ask. I know the starter clutch is gonna go one of these days. If I have to pull the engine and split the case, I'd rather find something bigger to put back in.
 
Just wanted to give everyone a heads up on a salvage yard company. I ordered the chain and 2 sprockets from Babbitt's only to find out the generator shaft sprocket has been discontinued. I put out a request for salvage yards and most came back from $20 to $60. When the sprocket was available new, it was about $70. I had one company, Oz Powersports in Kansas, come back with a quote for $195! I mentioned that price was a bit high and gave him the prices that other salvage yards had quoted me. His response:
I show its discontinued. If its only $70 new, I wouldn’’t waste any more of everythings time and would just buy it new.

Oz Powersports

He knows he has a part that's discontinued but it came off a half dozen different models from that era and probably isn't in real high demand. Nothing I dislike worse than someone trying to really gouge you for parts. For the record, I am calling someone this morning, Steves Cycle Salvage, $40. Sold.
 
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Unfortunately, Oz Powersports are like that. I tried to get some KZ parts from them and had the same treatment. Another rider friend of mine swears by them, but as far as I'm concerned, they're just another dark hole in this state.
 
I wonder what the difference is between the generator sprocket on the zl and the zg sprocket??
12046-1068

Need to find alternatives!
 
Looks like you can use the newer zg parts. The generator shaft is the same part# but the dampers(92075-1810 X4) the boss sprocket(13061-1183) and the generator sprocket(12046-1083) would probably have to be used together. They also list a different chain and crankshaft sprocket. Only thing I would be concerned about is if the crankshaft sprocket and chain could be swapped, you can't x-ref the cranks because they are definetly different part #'s. But they do use the zl900 parts on the zl1000. The zl1000 shares the same crank as the newer zg1000's(2004 i checked for sure) So it's safe to assume that the zg1000 sprockets and chains could be swapped so long as you replace the dampeners and boss sprocket as well.


Here's a comparison of part numbers between the zl900 A1 and the 2006 zg1000A6F:
Generator shaft 13107-1108 both models
Generator sprocket 12046-1068(zl900/1000) 12046-1083(zg1000)
Dampener Couplingx4 92075-1790(zl900/1000) 92075-1810(zg1000)
Boss sprocket 13061-1111(zl900/1000) 13061-1183(zg1000)
Washer 92022-1519 both models
Nut 315G1600 both models

crankshaft side:
Chain 92057-1292(zl900/1000) 92057-1209(zg1000)
Sprocket 21T 12046-1067(zl900/1000) 12046-1084(zg1000)
Washer 92022-1633 both models
Flanged Bolt 130G0825 both models
 
Now the alt chain tensioners and guides have different #'s as well

Alt Chain Tensioner 39170-1053(zl900/1000) 39170-1055(zg1000)
Alt Chain Guide 12053-1138(zl900/1000) 12053-1189(zg1000)
 
Price breakdown for ZG items (via Bike Bandit) if everything was a direct fit:

<TABLE class="Basket BasketGrid" cellSpacing=0 cellPadding=5 border=0><TBODY><TR class=BasketHeading><TD width=25>Qty.</TD><TD>BikeBandit.com
Part Number
</TD><TD class=BasketDesc width=350>Description</TD><TD width=48>Unit Price</TD><TD width=57>Your Price</TD><TD width=64>Total
Price
</TD></TR><TR><TD class=BasketGridL align=middle><INPUT type=checkbox value=0 name=delete_item> </TD><TD align=middle><INPUT maxLength=3 size=2 value=1 name=qty_0> </TD><TD vAlign=top noWrap align=middle>541543-001

</TD><TD class=BasketDesc vAlign=top><TABLE cellSpacing=1 cellPadding=0 width="100%" border=0><TBODY><TR><TD style="BORDER-TOP-WIDTH: 0px; BORDER-LEFT-WIDTH: 0px; BORDER-BOTTOM-WIDTH: 0px; BORDER-RIGHT-WIDTH: 0px" vAlign=top>SPROCKET,GENERATOR </TD></TR></TBODY></TABLE><TABLE cellSpacing=1 cellPadding=0 border=0><TBODY><TR><TD class=BasketDetails colSpan=2>Kawasaki 2006 Concours(ZG1000A6F (US)) BALANCER </TD></TR></TBODY></TABLE></TD><TD align=right>$61.72</TD><TD align=right>$61.72</TD><TD class=BasketGridR align=right>$61.72</TD></TR><TR><TD class=BasketGridL align=middle><INPUT type=checkbox value=1 name=delete_item> </TD><TD align=middle><INPUT maxLength=3 size=2 value=4 name=qty_1> </TD><TD vAlign=top noWrap align=middle>631742-001

</TD><TD class=BasketDesc vAlign=top><TABLE cellSpacing=1 cellPadding=0 width="100%" border=0><TBODY><TR><TD style="BORDER-TOP-WIDTH: 0px; BORDER-LEFT-WIDTH: 0px; BORDER-BOTTOM-WIDTH: 0px; BORDER-RIGHT-WIDTH: 0px" vAlign=top>DAMPER,COUPLING </TD></TR></TBODY></TABLE><TABLE cellSpacing=1 cellPadding=0 border=0><TBODY><TR><TD class=BasketDetails colSpan=2>Kawasaki 2006 Concours(ZG1000A6F (US)) BALANCER </TD></TR></TBODY></TABLE></TD><TD align=right>$6.40</TD><TD align=right>$6.40</TD><TD class=BasketGridR align=right>$25.60</TD></TR><TR><TD class=BasketGridL align=middle><INPUT type=checkbox value=2 name=delete_item> </TD><TD align=middle><INPUT maxLength=3 size=2 value=1 name=qty_2> </TD><TD vAlign=top noWrap align=middle>544721-001

</TD><TD class=BasketDesc vAlign=top><TABLE cellSpacing=1 cellPadding=0 width="100%" border=0><TBODY><TR><TD style="BORDER-TOP-WIDTH: 0px; BORDER-LEFT-WIDTH: 0px; BORDER-BOTTOM-WIDTH: 0px; BORDER-RIGHT-WIDTH: 0px" vAlign=top>BOSS,SPROCKET </TD></TR></TBODY></TABLE><TABLE cellSpacing=1 cellPadding=0 border=0><TBODY><TR><TD class=BasketDetails colSpan=2>Kawasaki 2006 Concours(ZG1000A6F (US)) BALANCER </TD></TR></TBODY></TABLE></TD><TD align=right>$47.34</TD><TD align=right>$47.34</TD><TD class=BasketGridR align=right>$47.34</TD></TR><TR><TD class=BasketGridL align=middle><INPUT type=checkbox value=3 name=delete_item> </TD><TD align=middle><INPUT maxLength=3 size=2 value=1 name=qty_3> </TD><TD vAlign=top noWrap align=middle>628506-001

</TD><TD class=BasketDesc vAlign=top><TABLE cellSpacing=1 cellPadding=0 width="100%" border=0><TBODY><TR><TD style="BORDER-TOP-WIDTH: 0px; BORDER-LEFT-WIDTH: 0px; BORDER-BOTTOM-WIDTH: 0px; BORDER-RIGHT-WIDTH: 0px" vAlign=top>CHAIN,GENERATOR </TD></TR></TBODY></TABLE><TABLE cellSpacing=1 cellPadding=0 border=0><TBODY><TR><TD class=BasketDetails colSpan=2>Kawasaki 2006 Concours(ZG1000A6F (US)) CRANKSHAFT </TD></TR></TBODY></TABLE></TD><TD align=right>$47.30</TD><TD align=right>$47.30</TD><TD class=BasketGridR align=right>$47.30</TD></TR><TR><TD class=BasketGridL align=middle><INPUT type=checkbox value=4 name=delete_item> </TD><TD align=middle><INPUT maxLength=3 size=2 value=1 name=qty_4> </TD><TD vAlign=top noWrap align=middle>585547-001

</TD><TD class=BasketDesc vAlign=top><TABLE cellSpacing=1 cellPadding=0 width="100%" border=0><TBODY><TR><TD style="BORDER-TOP-WIDTH: 0px; BORDER-LEFT-WIDTH: 0px; BORDER-BOTTOM-WIDTH: 0px; BORDER-RIGHT-WIDTH: 0px" vAlign=top>TENSIONER-COMP </TD></TR></TBODY></TABLE><TABLE cellSpacing=1 cellPadding=0 border=0><TBODY><TR><TD class=BasketDetails colSpan=2>Kawasaki 2006 Concours(ZG1000A6F (US)) CRANKCASE </TD></TR></TBODY></TABLE></TD><TD align=right>$109.61</TD><TD align=right>$109.61</TD><TD class=BasketGridR align=right>$109.61</TD></TR><TR><TD class=BasketGridL align=middle><INPUT type=checkbox value=5 name=delete_item> </TD><TD align=middle><INPUT maxLength=3 size=2 value=1 name=qty_5> </TD><TD vAlign=top noWrap align=middle>541779-001

</TD><TD class=BasketDesc vAlign=top><TABLE cellSpacing=1 cellPadding=0 width="100%" border=0><TBODY><TR><TD style="BORDER-TOP-WIDTH: 0px; BORDER-LEFT-WIDTH: 0px; BORDER-BOTTOM-WIDTH: 0px; BORDER-RIGHT-WIDTH: 0px" vAlign=top>GUIDE-CHAIN </TD></TR></TBODY></TABLE><TABLE cellSpacing=1 cellPadding=0 border=0><TBODY><TR><TD class=BasketDetails colSpan=2>Kawasaki 2006 Concours(ZG1000A6F (US)) CRANKCASE </TD></TR></TBODY></TABLE></TD><TD align=right>$11.66</TD><TD align=right>$11.66</TD><TD class=BasketGridR align=right>$11.66</TD></TR><TR><TD class=BasketGridL align=middle><INPUT type=checkbox value=6 name=delete_item> </TD><TD align=middle><INPUT maxLength=3 size=2 value=1 name=qty_6> </TD><TD vAlign=top noWrap align=middle>541543-001

</TD><TD class=BasketDesc vAlign=top><TABLE cellSpacing=1 cellPadding=0 width="100%" border=0><TBODY><TR><TD style="BORDER-TOP-WIDTH: 0px; BORDER-LEFT-WIDTH: 0px; BORDER-BOTTOM-WIDTH: 0px; BORDER-RIGHT-WIDTH: 0px" vAlign=top>SPROCKET,GENERATOR </TD></TR></TBODY></TABLE><TABLE cellSpacing=1 cellPadding=0 border=0><TBODY><TR><TD class=BasketDetails colSpan=2>Kawasaki 2006 Concours(ZG1000A6F (US)) BALANCER </TD></TR></TBODY></TABLE></TD><TD align=right>$61.72</TD><TD align=right>$61.72</TD><TD class=BasketGridR align=right>$61.72</TD></TR><TR><TD class=BasketGridL noWrap align=middle colSpan=2 height=43><INPUT type=image height=29 alt="Update Order" width=77 src="http://www.bikebandit.com/img/btn_update.gif" value="Update Order" border=0 name=Update> </TD><TD class=BasketGridR noWrap colSpan=3 height=43>
​


</TD><TD class=BasketSubtotalL>Subtotal:</TD><TD class=BasketSubtotalR>$364.95</TD></TR></TBODY></TABLE>


Not too bad IMO. I wonder what the major differences are.
 
well thats a lot of jack,, but if you need to do it I think it's a bolt on providing you use the whole shebang. Here's pics, notice the additional width in the zg chain, which i'm sure carries through on the sprockets, guide and tensioner.
 

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Might want to sticky some of this info for the tech section. I just went with the stock parts this time (new chain and crank sprocket, salvage gen shaft sprocket) due to time constraints and $$. Might be helpful to others down the road.
 
tagged for now.........
It's a shame, they beefed up the chain and sprockets but the tensioner is still the weakest link
 
Not what you wanna find!!!!:BangHead: Talked to Gremlin early about this and he is gonna hook a brother up...still sucks..now gotta pull the oil pan and clean the gears out!!:angry4:Every time I get this thing up and running good, BOOM another tear down!!! But you gotta pay to play!!!! And I LOVE TO PLAY WITH MY ZL!!!:headbang:
 
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when it let go were you on the throttle hard? sorry 2 see that but im sure you can fix it up with 1 eye closed as many times you have turned a wrench on that nasty biotch! good luck.
 
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