Don't try to run the engine anymore! The piston hit the plug on that cylinder for some reason. You have a teardown ahead of you. Ask questions as needed as you go. Take lots of pictures and label everything you take apart, so you know how it goes back together. And get a factory service manual. There are several download links here for it in .pdf format.

 

Def take it apart. Sounds like maybe a broken rod? Just hasn't punched out the side of the case yet... Def don't run it anymore. Open her up and if ur lucky a new piston rod and maybe valves will do it... I have a rod and piston to sell U cheap when u get there...

 

[Thanks for the input. I will post my progress and hopefully I am sure with the help of everyone, the bike will be back on the road in due time.

Here is a picture of the bike that I just purchased. And here's a picture of my 04 that I purchased new (completely stock still).

 

get that Honda out of the way of that great looking BLUE zx12r :king:


Oh and good luck with the engine rebuild
me I wouldn't have turned it over if I couldn't by hand.
:thumbup:

 

Update...I just finished taking the oil pan off the motor. Never seen such a mess nor would have imagined that all this could end up in the oil pan.

I am guessing this means the motor is basically "done" and I will need to look for another motor?

 

Depends on the actual cases and condition. You might be able to still rebuild that one.

 

That blue one looks just like my 2002 zx12r.

 

A few bits missing there but some super glue will soon have it all back together, for an ornament at least. :thumbup:

 

You meant JB weld:runaway:

 

If I may ask, I found another motor that is guaranteed good. Does anyone know if the motor from an 02 will bolt up, plug and play in my 2001? I still plan to try and repair the bad one just for the educational value tho.

 

A 02 engine should work just fine with wire harness and ecu in your 01. The only difference between the two is the front motor mount the 01 has a wish bone style that bolts above#1 and #4 cylinders. The 02 and up has a much smaller mount that bolts above #2 and #3 cylinders. The motor can easily be swapped without a hitch. All you would need to do is drill and tap holes in the 02 motors head to accommodate the 01 motor mount. There is actually spots on the 02 head with added material above #1 and #4 that make it quite simple to do. If it was me I would go that route if you can pick up the 02 motor for a decent price.

 

Different engine mounts...amongst other things. If you get the ECU and wiring harness, that will eliminate that. A and B model engines bolt in different. Can be done, but you will have to fab parts yourself.

 

**UPDATE** - Engine Failure

Finally got the engine out of the bike. Not hard at all to remove. Was surprised that I could do it alone without the help of someone to steady the engine.

So, I took the head off and found (as expected) that the piston was destroyed, the connecting rod is still intact. However, the cylinder wall in two spots is scored pretty bad from the pin that connects the piston to the connecting rod.

Here is a pic of what i found when I removed the head.

Removed the oil pan and the when i grab the bottom of the rod, there is a little movement from side to side. Not much but there is movement. I guess I need to read the manual and buy the necessary measuring tool to see if the movement is within acceptable standards.

 

Wow. It is a testament to Kawasaki and it's engine design that that thing even started after that!

Get her torn down and see if there is any other damage. You may be able to rebuild that motor....

 

Let me know if you need any help. I'm pretty good with my hands and feet.

 

metalmagician...thanks for the offer. I welcome all the help you can give. Never attempted such a task and I hope I am not in over my head.

 

Just took a look at the intake/exhaust valves...unless, the experts on here say different, I would say this head is done/caput! haha

 

That head is toast. The only thing useful on that engine is parts and the cases most likely. New jugs and head time. Possibly crank. Seeing this, if you can score another complete good engine, you may way to explore that route, unless you want to build a bad ass bike....

 

If you can remove and install the engine than you will be able to use the 02 motor. The swap is pretty much a straightforward process. Don't discredit yourself so soon I'm sure someone can drill and tap the proper holes for you. I wish you the best of luck getting that beast back on the road.

 

Agreed. Tapping the holes ain't gonna be that hard. Measure the depth of the existing holes, mark that oj a series of bits, make sure your angle is straight and go for it. Then use the correct tap. Getting the angle and depth right is the hardest part. Gotta have a steady hand....

 

Thanks for all the input. Does anyone know why parts for a 2001 ZX12R are not listed on parts sites (i.e. worldofpowersports.com). It seems like they skipped 2001. I can find parts list for the 2000 and 2002, but not the 2001. So, do I just use the 2000 engine parts list for my 2001 ZX12r?

 

I usually source my parts at powersedge motorsports out of Michigan and then if they are cheaper, take those prices to my local Kaw dealer and price match and order from there. They have the 2001 listed.

 

Was hoping to save the cylinder but, as luck would have it, the cylinder is trashed. The more I tear into the motor, I think to just buy another engine. However, it's getting personal now and I refuse to let another motor just end up as junk. Been looking around and the ZX12 motor is getting hard to find, even engine components. So, I am committed to rebuild this motor and see it through until I hear the thing run again.

 

Source a good head. Find a good set of aftermarket rods, pistons and jugs...check the crank for damage. Like I said, you can rebuild this one. It just depends on how committed you are to the task....financially and emotionally...but running, she won't disappoint ya. That much I can tell ya. It's up to you if you keep stock displacemet or bump it up a bit...

 

"Been looking around and the ZX12 motor is getting hard to find"

I have to disagree, nine of them on ebay this am. Not sure of yur rebuild budget but buying piece by piece will add up. A low mileage runner or an accident cracked case unit should be in your future. 03 or older will fit best, 04/05 will need a different wiring harness/ECU etc.

Good Luck.

....and you already have one, your just bein greedy:crackup:

 

weedy64...thanks for the information. Trying to understand this...i heard that an 02 will work but you will need to drill and tap the front engine head and that you will need the wiring harness and ECU. Then you are saying that a 03 or above will fit best, but that an 04/05 will need different wiring harness/ECU, etc. So, are you saying that an 03 will not require drilling and tapping the front engine head and also not need the different wiring harness? Sorry, and not doubting your mechanical knowledge of the ZX12, just a little confused from what I heard earlier on the site. Can anybody else shed some light on this?

 

00, 01, 02, 03 engines will all work with your existing wiring...02 and 03 will require you to drill and tap the head for your current motor mount. The spots are there, they are just not drilled and tapped. Same thing applies to 04 05 engines, but you will need the newer wiring harness of these bikes as it is different.

I would think myself that you would also need these harnesses for 02/03 because of the secondary butterflies in the B model bikes, but I could be wrong.

 

Spose...you could just use your current throttle bodies......then you'd be alright...