Installed the JOG today

Beast · 03-28-2013, 11:08 PM

So far so good. 20K on a 99 Nomad. Still had the plastic gear. I got alot of help from Bob, wolfmil042370, He had many useful tips. This is the latest JOG from Judge. It only took a couple of weeks to get it. Cranked it first without the plugs to seat it into the clutch basket gear. Also add the Mean Streak spring and judges washers. Added the throttle cable modification. Heading to Carmel for a week to chase wineries and the small ball. Riding with the boys on the 7th from the Sedalia Grill.

aron22 · 03-28-2013, 11:32 PM

How long did it take you to change it? I also have a '99 with 20 some k on it, I always have one eye on the oil light while I'm riding lol! I need to check mine!

**ringadingh** · 03-29-2013, 09:56 AM

Thats good that you changed it, most likely it would have quit at the worst possible time.

cactusjack · 03-29-2013, 11:18 AM

Quote:

Originally Posted by Beast

So far so good. 20K on a 99 Nomad. Still had the plastic gear. I got alot of help from Bob, wolfmil042370, He had many useful tips. This is the latest JOG from Judge. It only took a couple of weeks to get it. Cranked it first without the plugs to seat it into the clutch basket gear. Also add the Mean Streak spring and judges washers. Added the throttle cable modification. Heading to Carmel for a week to chase wineries and the small ball. Riding with the boys on the 7th from the Sedalia Grill.

I've actually been to the Sedalia Grill. Small world.

**Jared** · 03-29-2013, 11:29 AM

Nicely done!

ndbigfish · 03-29-2013, 09:24 PM

Did you check the tabs on the back of the clutch basket? The tabs ate up a gear on my first attempt. The second attempt went better.

Sin City Stan · 03-30-2013, 07:23 PM

You know I've heard allot about this plastic gear but I never saw it in the wild. Looking at the first picture all I have to say is what was Kawasaki thinking??? I mean it even looks wrong.

**cnc** · 03-30-2013, 10:05 PM

Quote:

Originally Posted by Sin City Stan

You know I've heard allot about this plastic gear but I never saw it in the wild. Looking at the first picture all I have to say is what was Kawasaki thinking??? I mean it even looks wrong.

Not that new an idea Stan, GM used nylon toothed timing chain sprockets in many of their engines in the late 60's and 70's. I think they finally switched to all steel sometime in the 80's. I stripped a few teeth off of more than one 327.

danimal2 · 03-31-2013, 09:16 AM

Quote:

Originally Posted by cnc

Not that new an idea Stan, GM used nylon toothed timing chain sprockets in many of their engines in the late 60's and 70's. I think they finally switched to all steel sometime in the 80's. I stripped a few teeth off of more than one 327.

1972 Mercury Capri 2600 V6 had a timing set that was nylon/plastic gear to gear (no chain). Mine blew apart too. Fortunately in that instance they learned their lesson and the replacement parts were all steel. There are some applications where you might be able to get away with it, but not an oil pump, timing set, or other critical pieces.

**minst7877** · 03-31-2013, 10:10 AM

I rermember changing out timing chains ang gear in my younger days. It seemed strange that all the replacement gears were steel and the originals were nylon. The nylon did run quieter than the steel replacements. Those were also the days that engines were not expected to last 100000 miles.

DC

Sin City Stan · 03-31-2013, 12:19 PM

Quote:

Originally Posted by cnc

Not that new an idea Stan, GM used nylon toothed timing chain sprockets in many of their engines in the late 60's and 70's. I think they finally switched to all steel sometime in the 80's. I stripped a few teeth off of more than one 327.

My point exactly. This was an experiment to reduce engine noise over 20 years earlier. Didn't work then. What made Kawasaki think it would work in 1999. Same here with the 327s.

**cnc** · 03-31-2013, 12:36 PM

Quote:

Originally Posted by Sin City Stan

My point exactly. This was an experiment to reduce engine noise over 20 years earlier. Didn't work then. What made Kawasaki think it would work in 1999. Same here with the 327s.

Maybe they thought they had superior plastics than 20 years ago.

I do have a small metal lathe that has a plastic gear in it and it is surprisingly tough. Some guys replace it with a steel gear, but I never have. The idea behind that design is if something happens the gear will break and save big damage, kinda like a fuse.

johnberryus · 04-02-2013, 05:27 PM

Quote:

Originally Posted by Beast

So far so good. 20K on a 99 Nomad. Still had the plastic gear. I got alot of help from Bob, wolfmil042370, He had many useful tips. This is the latest JOG from Judge. It only took a couple of weeks to get it. Cranked it first without the plugs to seat it into the clutch basket gear. Also add the Mean Streak spring and judges washers. Added the throttle cable modification. Heading to Carmel for a week to chase wineries and the small ball. Riding with the boys on the 7th from the Sedalia Grill.

Spent many a Sunday at the Sedalia Grill usually on my way back from Palmer Lake after a steak at O'Malleys. Moved out to Cali three years ago from Thornton. Let me know if you need a couple of good routes down near Monterey I got a few favorites down there.

Beast · 04-09-2013, 10:09 AM

I also installed the Judge washers, the Meanstreak spring and the throttle modification. Two things I noticed on the test drive yesterday. Faster response on the throttle and I no longer have the heavy clunk from neutral into first. The instructions warned about rear tire lockup on down shifting and harder to pull the clutch in. I didn't have either problem.
Aron22, I can't say how long it took. Since, with the forums help, I'm a self taught wrench jockey, I never rush projects like this. I'd say if a guy is familiar with engines and has a shop manual it could be done in i/2 a day.

Beast · 04-09-2013, 10:16 AM

Quote:

Originally Posted by ndbigfish

Did you check the tabs on the back of the clutch basket? The tabs ate up a gear on my first attempt. The second attempt went better.

I have to admit I didn't have a clue what the tabs were. There was nothing obvious to me. Bob, wolfmil042370 helped me out. On the back of the clutch basket are 6 horizontal springs about 1" long in a circular pattern. Each one has a steel tab on either side. These need to be below the main drive gear. Here is the part I never would have figured out. You have to take a ball peen and set it on top of the tab then hit it hard with another hammer. Check clearance again and repeat for all tabs. A total of 12. I probably had 6 too high. So I hit them all. Thanks Bob

03-29-2013, 09:56 AM	#3
ringadingh Join Date: Aug 2007 Location: Newmarket Ontario Canada Posts: 35,387	Thats good that you changed it, most likely it would have quit at the worst possible time. __________________ 2002 Nomad aka Bountyhunter VBA #27 VROC #18951
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03-29-2013, 11:29 AM	#5
Jared Join Date: Mar 2009 Location: Greeley, Colorado Posts: 6,772	Nicely done! __________________ Jared VBA #1051 (Former President) Login or Register to Remove Ads
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03-29-2013, 09:24 PM	#6
ndbigfish Sr. Member Join Date: Mar 2009 Location: New Braunfels, Texas Posts: 1,162	Did you check the tabs on the back of the clutch basket? The tabs ate up a gear on my first attempt. The second attempt went better. __________________ Brik VBA #1047 07 Electra Glide Ultra (43,300 & counting) 03 Nomad - 37,972 (traded 5/6/13) 99 Nomad - Only a memory since 4/27/13
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03-30-2013, 07:23 PM	#7
Sin City Stan Sr. Member Join Date: Mar 2009 Location: Henderson, NV Posts: 3,746	You know I've heard allot about this plastic gear but I never saw it in the wild. Looking at the first picture all I have to say is what was Kawasaki thinking??? I mean it even looks wrong. __________________ Oldest Saloon In Nevada http://www.pioneersaloon.info/ "Sin City Stan" Henderson, NV VBA #01004 VROC #29365 2004 Nomad 1500L5 +100 "The Bike" 2009 Nomad 1700 (past) 2004 Vulcan Classic 800 (past) 2010 Cortez - 2011 Crescent City - 2012 Kanab - 2013 Estes Park
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03-31-2013, 10:10 AM	#10
minst7877 Join Date: Oct 2010 Location: Michigan Posts: 1,286	I rermember changing out timing chains ang gear in my younger days. It seemed strange that all the replacement gears were steel and the originals were nylon. The nylon did run quieter than the steel replacements. Those were also the days that engines were not expected to last 100000 miles. DC __________________ Me and my 99 G1 Nomad on US 2 by the Lake Michigan Shoreline. Judge's Oil Gear failed and engine overhauled @ 35563 miles VBA/KawaNOW #01625 Christian Motorcyclists Assoc. Wheels Of Destiny Chapter #735 PA Wilds NE/Eastern Canada regional rally July 2012 Eureka Springs National 2015 Rolling Thunder Washington DC 2016 NE US / E Canada Rally - Mont Tremblant, QC 2016 VRA Eastern National at Maggie Valley 2017 99 Nomad G1 gone but never forgotten traded 4/8/17 for a 2017 Indian Roadmaster
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03-28-2013, 11:32 PM	#2
aron22 Jr. Member Join Date: Jun 2011 Location: Alta IA Posts: 21	How long did it take you to change it? I also have a '99 with 20 some k on it, I always have one eye on the oil light while I'm riding lol! I need to check mine!
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04-09-2013, 10:09 AM	#14
Beast Member Join Date: Jan 2013 Location: Denver Posts: 73	I also installed the Judge washers, the Meanstreak spring and the throttle modification. Two things I noticed on the test drive yesterday. Faster response on the throttle and I no longer have the heavy clunk from neutral into first. The instructions warned about rear tire lockup on down shifting and harder to pull the clutch in. I didn't have either problem. Aron22, I can't say how long it took. Since, with the forums help, I'm a self taught wrench jockey, I never rush projects like this. I'd say if a guy is familiar with engines and has a shop manual it could be done in i/2 a day.
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