Taken chain adjusters off a zzr 1100 is there a certain way to put them back?

SOURCE: zzr gear box

I have been a bike mechanic for over 10 years and never seen this one before. The only thing I can even think of is a broken shift fork. This would let a slider gear wander freely and potentially engage a gear while the bike is already in a different gear. This would account for the rear wheel lock up. The 'tight spot' would probably be a torqued and twisted shaft resulting from the lock up.

The repair will be major surgery on the tranny. Personally, I would replace all shafts, all gears and all shift forks. You don't know and can't just look and see what stress has been put on any individual gear. I would hate to see you put in a few gears, put the engine back in the bike, then find a stressed gear dropping a couple of teeth the first time you hit second. To put it another way, get a new tranny and a new chain. The chain was stressed also. Sorry about the bad news.

Ask the dealer what the cost would be to replace the entire tranny but not the clutch. Now Google ' salvage motorcycles kawasaki ' and see what an entire used engine would cost. Chances are the engine swap that you can do yourself will cost less than the dealer's repair of the current tranny.

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SOURCE: find oilfilter location on kawasaki zzr 1100

Bottom of motor there is about a 31/2" round cover with a bolt through the middle thats the filter you may have to remove the exhaust to get to it on your bike

SOURCE: How do i remove the back wheel of my ZZR 1100 1996

It is not necessary to release the alignment adjusters to remove the rear wheel so you need have no fear about that.

The first thing I do is put the bike on the centre stand with an inch thick plank of wood under the stand to give a bit of extra clearance when removing the wheel.

The only tricky thing is having the appropriate tools to undo the axle nut. If you don't have the original tool kit you will need to go and do some shopping for large allen keys.

Now all you have to do is remove the two retaining clips, slacken and remove the axle nut and pull out the axle - it can help to tap this from the nut end with a piece of broom handle or similar, and another pair of hands can be useful as the rear wheel is not light weight and needs a little manoeuvring.

Lift off the chain and hang it on the swinging arm and the wheel can be lifted out. Take care not to rest the wheel on the brake disc!

SOURCE: idle speed adjuster fell

RH side on the carbs under the throttle cable connection to the carbs. Screws in from below. You'll have to loosen the fearing to get at it.

SOURCE: 1994 ZZR 1100 - for

If you examine the failed plug and check the condition of it. It could be overheating, oil up, carbonize. Not enough information for me to cast an oppinion.
Check your owners manual to see what the plug should run like. If it is overheating, try a harder plug.