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Discussion Starter #1
Hi!

First time actually posting something and I have to admit it ain't looking good...

Last ride I had with my beloved '03 B2 the engine started making some clunki9ng noise shortly after launching on highway...finding this extremely strange I stopped and my buddy and I checked the sound source; middle to top of engine (might be wrong on that,sounds tends to bounce as you know).

Decision was then made to turn around and bring it to the garage for assesment. After about 10 min on the way back (at about 1km from home) the battery actually died on me and absolutely nothing worked anymore. No flashers,no gauge display...absolute dead. Pushed it back to the garage (downtown Montreal @ 17h00 on thursday...traffic heavy and taxis honking).

So I finally had time to check it and so far,the battery is dry dead and a replacement is due tomorow. My guess is it'll start,more on that soon.

I suspect stator/rotor of shattering into pieces or something near which in turns stopped recharging the battery,10-12 min laters,out of juice,the engine had no other choice than to stop.


What are you guys thinking? Is this unusual or did any of you had this problem before?

Thanks for checking this thread!
 

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Sounds like when my 2000 zx12r oem clutch basket went kaboom................
 

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Sounds to me like magnets around the stator have come adrift.....might explain the noise and as such caused the battery to go bad ?.
Your starter motor don't do anything towards charging the battery, but I guess it could cause a short to drain the battery ?.
 

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I have never once, in a long time of working on and riding bikes, heard of a stator shattering.

If I had to guess blindly, something made your battery croak and what you think was the cause is actually a symptom (a dying battery will cause misfiring at the start before the bike dies completely and they will buck, snort and bitch including cam chain noise as they misfire).

A good fully charged battery will run a bike with no alternator on a race track for 20-25 minutes.

Checking your stator is a 5 minute deal, however as L2M said it does sound like a fried stator wiring harness to me too - even though that was supposed to be fixed in the B models.
 

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that was supposed to be fixed in the B models.
My 2003 had the oil creep into the stator wires. Easy fix, I would definitely take a look at it. As for the boom? No clue. Weird things happen to motorcycles when the batteries die.
 

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The 12 is very hard on batteries, partly because of the rubbish electrical system fitted by Kawasaki and partly because of the size if the engine and gearing. When your bike is at idle it is not charging your battery, it’s actually draining it. The battery only starts to charge around 2500-3000rpm. Depending on your bikes gearing and the way you ride you could be discharging the bike in the cruise. For example, with standard gearing you could be doing 70ish MPH in top [email protected] RPM. All it takes is for you to back off the throttle a little in top gear and you’re not spinning the rotor fast enough to charge the battery. A trickle charger and a watchful eye on the stator harness and connector should be all that’s needed to keep it in top condition.:thumbup:
 

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I have had the same battery in my 12 since I brought it home 4 years ago. I must have gotten a Wednesday bike. It's an AGM battery from Batteries Plus. Still starts the bike like the day I brought her home in 2008.....So I'm not willing to go so far to say that the machine is hard on batteries. Perhaps there are other things at work here...

There are soooooo many moving parts inside an engine, it's foolish to try and speculate what may have went boom. The battery may be secondary event here. Take the left cover off and look at your stator and rotor. If you exploded a stator, I would love to see pics cause I've never heard of a stator exploding in all my years in engines....they are quite robust. you could prolly shoot it with a cannon and it'd still be in damn near 1 piece I bet.

As for the rotor....never seen one of these go either, but I wouldn't put it out of the realm of possibility.

It IS possible that the bolts holding your stator wiggled loose, as they do if you don't use loktite to put them back in and made contact with the rotor and this was the clunking you were hearing.

Pull the cover and look. That is the ONLY way you are gonna know for sure.

:thumbup:
 

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Discussion Starter #9
Update

Thanks for all the replies guys,really appreciated.

Got a Yuasa brand new battery in and a trickle charger installed too.

The bike started as if it were new,no problem at all,engine noise was totally fine...until you rev it up.

The sound is clearly (at least to my ear) from a loose chain grinding everywhere and it amplifies as the revs go higher.

I'm reading through the 613 pages zx12r manual to check point by point but my guess is a loose chain/bearing or something like that.

Is the rotor spun by chain or by direct gearing through the engine?

Also,where is that damn chain tensionner...can'T seem to find it.


Last minute detail: My bike is loosing oil,bit by bit. The mechanics changed the engine gaskets last summer and cleaned it and said he didn't find any reason for oil to be there but still,there is oil again. It's low on the left side,right in front of the shifter :)headscratch: isn't it odd that's it beside the alternator..uh uh...)

I'm working on it today and when I find something,I'll keep you guys posted.
In the mean time,any suggestion is welcome.

Thanks
 

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Discussion Starter #10
Holy "$"$"/$"%/$?%$&?* .

Just decided to check the cam chain tensionner and had a quick look at the oil window....it's dead dry. The mother %?$ light didn't come on EVER.

Now I might have much worst problems....

So oil leaked out,something broke and battery stopped charging...

What might be the link between all of this??



(Yes,I am ashamed of not having a look at this damn thing before)
 

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Drain the oil. Look for debris. It may have settled but the real x-ray is to cut open the oil filter. If it is filled with copper or brass colored bits, combined with silver or [soft] aluminum crank/rod bearing layer, then the tolerance is your knock. Without knowing, last thing you want to do is add more oil and keep churning on and spinning out clutter that you can salvage the engine with less time on it. Literally, it takes seconds to waste an engine.

If the oil filter pleats are spotless, then all you are hearing is a louder bellowing sound of the noise in the crankcase. The big basket can't quiet down, because that and the chain whipping cannot bang on oil splash. It more bangs in the air, not in that oil cushion.

Don't put a dime or drop in it until that filter is ripped open.

NOLTT
 

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Put some oil in it. That might take care of the noises...lubrication helps.

If not...

Try manually adjusting the cam chain tensioner by loosening the 2 bolts ONLY 1/4 to 1/2 turn then tighten back up. TRY A 1/4 TURN FIRST!. It don't take much to go to the next spline on the shaft. I loosened mine 1/4 turn and tapped LIGHTLY with a hammer and snugged back up. Chain noise gone.

:thumbup:
 

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Discussion Starter #13
Tensionner removed,checked and replaced all according to the manual.

Oil added to the correct level,engine ran great,the rattling sound is still present.

This bike is going to the mechanic now,I ain't gonna start it again until it's fixed,as you guys said,it could seize in seconds....


Quick question: you guys ever lost a frame bolt due to vibration?



I'll keep you guys posted asap. Thanks and merry Xmas!
 

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Are you talking about the bolts that attach to the frame from a bracket that is attached to the middle of the head in the front? If so then yes I had one fall out and the other one snapped off.
 

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Put some oil in it. That might take care of the noises...lubrication helps.

If not...

Try manually adjusting the cam chain tensioner by loosening the 2 bolts ONLY 1/4 to 1/2 turn then tighten back up. TRY A 1/4 TURN FIRST!. It don't take much to go to the next spline on the shaft. I loosened mine 1/4 turn and tapped LIGHTLY with a hammer and snugged back up. Chain noise gone.

:thumbup:
My12r, I suggested the same procedure on a different forum and got some interesting responses...........Zx6r cam chain : KawiForums.com Kawasaki Forums: Kawasaki motorcycle forums

+1 on the engine mounting bolts.
 
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