Z25 gear upgraded or not?
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Thread: Z25 gear upgraded or not?

  1. #1
    Junior Member
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    Tor Hånde
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    Z25 gear upgraded or not?

    I just opened up the clutch cover of my 2004 Tornado 900 RS today to check if my bike had the upgraded Z25 gear or not.
    I have enclosed a picture of the Z25 gear on my bike. Can anyone please tell me if this is the upgraded version? Z25 gear upgraded or not?-z25-gear.jpg

  2. #2
    Senior Member mikew124's Avatar
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    It looks like the latest gear.

    Details on what to look for here....

    Engine Checks

    Mike
    The TnT service DVD is now on You Tube
    https://www.youtube.com/watch?v=PLUiKULlIBo

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    Senior Member colintornado's Avatar
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    As Mike said,it is an upgraded gear and shaft. You can see the alignment triangles.The Old type were rough cast without alignment marks.
    RobShed likes this.
    Colintornado

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    Junior Member
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    Thanks guys! I just needed to be sure.

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    Quote Originally Posted by mikew124 View Post
    It looks like the latest gear.

    Details on what to look for here....

    Engine Checks

    Mike
    hi
    How do you separate the clutch basket assembly (to get from pic 3 to pic 4 ) exposing the retained springs ?
    Is it a press fit and need hydraulic pressure to get apart ?

  7. #6
    King of the Group-Buys Laurencewhite's Avatar
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    You need to drill out the rivets to separate the parts.
    Laurence

    Benelli Tornado 900 LE No. 49
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  8. #7
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    Quote Originally Posted by Laurencewhite View Post
    You need to drill out the rivets to separate the parts.
    thanks Laurence, that's what I thought, but how do you re build them ? rivets ? they look like huck bolts to me, some sort of cold formed cold collared rivet system.
    I have a perfect basket that I could rebuild .if I could attach it .

  9. #8
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    You'd probably need to source some solid steel cold forming rivets and get your best ball-pein hammer out. There doesn't appear to be enough room for a nut and bolt, even a huckbolt.

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    Quote Originally Posted by mikerj View Post
    You'd probably need to source some solid steel cold forming rivets and get your best ball-pein hammer out. There doesn't appear to be enough room for a nut and bolt, even a huckbolt.
    Take a hammer to my beloved Nellie s wash your mouth out with soap and water .
    This is what you find in taking it apart.
    DSCF0740.JPGDSCF0741.JPGDSCF0742.JPGDSCF0743.JPGDSCF0744.JPGDSCF0745.JPG
    I found it easier to drill out the domed head inside the clutch basket, to remove that. Hydraulic press to separate the two gear sets, careful not to lose the lock dowel.
    Drill the rivet remains out of the spring support plate and discard. Make a note what springs are where, three types , opposite each other radially .put a marker on the position of everything , although the lock dowel can only engage in the set position.
    I am sure I can find a better way of putting it back together, without hammers and steel cold formed rivets.
    where there is a will, there s a way.

  11. #10
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    Quote Originally Posted by Wiking View Post
    I just opened up the clutch cover of my 2004 Tornado 900 RS today to check if my bike had the upgraded Z25 gear or not.
    I have enclosed a picture of the Z25 gear on my bike. Can anyone please tell me if this is the upgraded version? Click image for larger version. 

Name:	Z25 gear.JPG 
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    I'd agree that looks like the upgraded version, but a word of caution , my trek had an upraded z25 upgrade and it still failed.
    I managed to catch it in time but the torsional twist on the splined shaft was clearly evident.

    I had removed the cover just as in your photo and seen the smooth z25 gear and the alignment marks so assumed all was ok. Also checked wth the main dealer who confrmed upgrade completed.

    Having the upgrade without checking the alternator end bolt and belville washer on a regular basis is a recipe for disaster as well as shearing the splines on the alternator .
    Speaking from experience.

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