Adjusting The Zx11 Oil Pan: A Step-By-Step Guide

The Kawasaki Ninja ZX-11 is a powerful motorcycle, but it has a history of issues with its oil pan. The #3 rod bearing is prone to failure due to insufficient oil pressure, which can lead to engine damage. To address this, some owners have opted for an aftermarket oil pan modification, such as the one offered by Mr. Turbo, which aims to improve oil flow to the #3 rod. This modification involves enlarging the oil hole in the #3 rod and ensuring proper alignment. While some have successfully performed this modification themselves, others have chosen to send their oil pan to specialists like Mr. Turbo for modifications. In addition to the oil pan mod, other engine modifications are often recommended, such as balancing and nitrating the crankshaft and boring the cylinders.

Oil pan modification for more oil to reach the #3 rod

To modify an oil pan for more oil to reach the #3 rod, you will need to make some adjustments to the oil pan and engine. Here is a step-by-step guide on how to perform this modification:

Step 1: Remove the Oil Pan:

Start by removing the oil pan from your ZX11 motorcycle. Drain the oil, remove the oil filter, and disconnect the oil lines that are fastened to the oil pan. Make sure to keep track of any washers or other small parts removed during this process.

Step 2: Access the #3 Rod Oil Hole:

With the oil pan removed, you will have access to the #3 rod oil hole. It is important to check the alignment of this hole to ensure that it is lined up correctly. If the hole is not lined up properly, you may need to use a round file or a Dremel tool to elongate it and create a proper passage for the oil.

Step 3: Modify the Oil Pan:

The goal of this modification is to increase oil flow to the #3 rod. You can achieve this by welding a sleeve or a patch panel to the oil pan, creating a larger capacity for oil. Make sure that any modifications made do not obstruct the oil return to the pump. It is recommended to have a junk block to practice your welding technique before attempting the final weld on the oil pan.

Step 4: Reinstall the Modified Oil Pan:

Once you have made the necessary modifications to the oil pan, it is time to reinstall it. Carefully clean all parts with brake cleaner or mineral spirits and a rag before reassembly. Reattach the oil lines, oil sending unit wire, and any other components that were removed during the disassembly process. Make sure to use a new gasket when reinstalling the oil pan to prevent leaks.

Step 5: Fill with Oil and Test:

After the modified oil pan is installed, fill the engine with the appropriate amount of oil. Start the engine and let it run for a few minutes. Check for any leaks around the oil pan gasket and tighten any connections as necessary. Take the motorcycle for a test ride and monitor the oil pressure and temperature to ensure that the modification has improved oil flow to the #3 rod.

It is important to note that this modification should be performed with caution and by someone with mechanical experience. Always refer to a service manual or seek advice from a qualified mechanic if you are unsure about any steps in the process.

Removing the oil pan

To remove the oil pan from a ZX11, you will need to drain the oil and remove the oil filter. Drop the lower fairing, then the exhaust, and remove the radiator as well. Drain the coolant into a clean container if you plan to reuse it. Next, remove the oil lines that are fastened to the oil pan, being careful not to lose any washers from the oil lines. Remove the oil sending unit wire by sliding off the rubber grommet to expose the screw. Take pictures of each part before removal so that everything goes back together properly. Clean all parts with brake cleaner or mineral spirits and a rag.

There is a gasket for the oil pan, so be sure to obtain a replacement before beginning this process. You may also want to replace the o-rings on the various pipes that go between the case and the oil pan, as well as new crush washers for the different oil line banjo bolts and copper gaskets for the exhaust.

Oil pan modification companies

Several companies offer oil pan modification services, and some also provide custom oil pans. Mr. Turbo, Muzzy, and Big Bike World are some companies that provide oil pan modifications for the ZX11. Mr. Turbo offers an oil bypass kit, which involves modifying the oil pan to improve oil flow to the #3 rod. Muzzy also offers a similar service, and they previously provided a billet oil pan for the ZX11.

In addition to these specialised services, there are companies that offer custom oil pans, which can be made to meet specific requirements. For example, Killarney Metals provides custom metal oil drip and drain pans for a variety of industries, including automotive repair and aviation. They offer pans in different materials, such as galvanised steel, stainless steel, and powder-coated steel, and can customise them according to individual needs.

Other companies that offer oil pans, though not specifically custom ones, include Bharat Automotive Pressings India Private Limited, Kannan Hydrol & Tools, and Autoverse Mobility Private Limited. These companies provide oil pans for a range of vehicles, including cars, tractors, and motorcycles.

Oil pump modification or replacement

The oil pump modification for the ZX11 is a popular procedure to improve oil flow to the #3 rod and prevent engine seizures. This modification involves changing the oil pan and rerouting the oil passage to ensure adequate lubrication during hard acceleration.

Step 1: Remove the Oil Pan

• Drain the oil and remove the oil filter.
• Remove the necessary parts to access the oil pan, such as the lower fairing, exhaust, and radiator.
• Disconnect the oil lines and sending unit wire from the oil pan.
• Carefully remove the oil pan, being mindful of any engine shavings.

Step 2: Modify the Oil Hole

• Check the alignment of the oil hole in the #3 rod bearing shell and its mate in the big end of the rod.
• If the oil hole is misaligned, use a round file or a Dremel tool to elongate it.
• Ensure that the oil hole is clear of any debris.

Step 3: Install the Modified Oil Pan

• Clean all parts with a suitable solvent, such as brake cleaner or mineral spirits.
• If using a replacement oil pan, ensure that it has the necessary modifications for improved oil flow.
• Reinstall the modified oil pan, ensuring that all gaskets and seals are in good condition.

Step 4: Check Oil Flow

• Before reassembling the engine, check the oil flow to the #3 rod.
• Ensure that the oil hole in the modified oil pan is lined up correctly.
• Verify that there are no obstructions in the oil passage.

Step 5: Reassemble the Engine

• Reinstall the oil lines and sending unit wire.
• Refill the engine with new oil and a new oil filter.
• Reattach the radiator, exhaust, and any other components removed during the process.

It is important to note that some ZX11 owners have reported issues with the stock oil pump not providing sufficient lubrication during hard riding. In such cases, an aftermarket oil pump or an auxiliary scavenge pump may be considered for improved performance and reliability.

Additionally, when performing the oil pump modification, it is recommended to inspect other components, such as the transmission and crankshaft, to address any potential issues proactively.

Oil level checks

Checking the oil level in a ZX11 can be a little tricky due to the way oil moves around the engine and the design of the sight glass. The key things to remember are to check the oil level when the bike is perpendicular to the ground (not on the kickstand) and to wait a few minutes after turning off the engine before checking.

When checking the oil level, make sure the bike is perpendicular to the ground. This can be done by having a friend hold the bike steady, using a mirror, or elevating the front wheel on the center stand so that both tires are the same distance off the ground.

It is recommended to check the oil level a few minutes after turning off the engine. This is because oil can drain into the balancer shaft chamber, lowering the level in the sight glass. Waiting a few minutes will allow the oil to be scavenged back into the main sump, giving an accurate reading.

When checking the oil level, it should be between the "low" and "top" marks on the sight glass. Some owners recommend keeping the oil level at or near the top mark to prevent oil starvation during hard acceleration.

It is important to note that the oil level may appear to drop over time, even without any leaks. This is due to oil draining into different parts of the engine and is not cause for concern. Checking the oil level consistently in the same manner will provide a parameter to monitor oil consumption.

Always remember to check for leaks and top off the oil as needed to maintain the proper level.

Frequently asked questions