GK73A

[N cee thirty]

just no alpha.
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[Noxious89123]

[CHR15]

right, well. since last time, the shock went back, was rebuilt again and seems to be leak free this time.

i've bolted on one or two brackets in the last few months, so its time to do a bit more.


the next big thing now is the engine. i need to totally strip and go through it to make a complete list of new parts needed.

all the consumable parts, shells / bearings / cam chain / seals / gaskets ect ect will be replaced along with anything else needed.

seeing as tims r1 rebuild was well received i thought it might be nice to post lots of pics to showcase miniature Japanese engineering.


so, engine on the bench.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1153Medium_zps99253c94.jpg

i already had an engine stand designed to fit 1100 oil boiler engines, it sort of fits but i need to make a pair of link bars, so the engine isnt sat on the sump as the 400 motor is smaller.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1154Medium_zpsa9c54ea4.jpg


best thing you can have when stripping japanese motors, a set of JIS (japanese industrial standard) screwdriver bits. (philips / pozidrive are designed to cam out when over torqued, jis arnt, which means they wont slip out and round off the screw)

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1156Medium_zps0819c064.jpg


any screws you see with a dot on the top are jis rather than philips.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1158Medium_zps4bb7bac4.jpg


rocker cover bolts and seals out. because the rocker cover is held in with shoulder bolts, when the seals shrink a bit they wont seal any more, so need replacing (especially as these ones are 24 years old)

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1157Medium_zps16baf663.jpg


rocker cover off, everthings where it should be which is a nice start

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1159Medium_zps3cfb61a3.jpg


one lobe on the inlet cam is a bit iffy.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1160Medium_zps7d511592.jpg


before you undo the cam caps the cct needs to come out to remove the preload from the cam chain

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1161Medium_zpsec95da7b.jpg


all cam caps removed and cams taken out. then i noticed one of the cam journals.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1163Medium_zps241adaa5.jpg

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1162Medium_zpsdb3582c0.jpg

far lhs on inlet. it seems to have picked up, but all the others are mint. on the lookout for a new head.



inlet rubbers and spacers removed

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1164Medium_zpsb2dbd28f.jpg

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1165Medium_zps1b773c19.jpg


spark plugs removed, looks like the fueling is pretty spot on

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1166Medium_zps82dff56e.jpg


water outlets unscrewed from head, all that sort of stuff will be zinc'd before re fitting.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1167Medium_zpsf101c212.jpg


main nuts removed

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1168Medium_zps8480726a.jpg


remember to take this little badger out.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1169Medium_zpsd09acf13.jpg


head and barrels pulled off

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1170Medium_zpsd61dc9f3.jpg


i tipped the barrels upside down to drain the remaining coolant and 2 m5 washers fell out. lol.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1171Medium_zpse1c755c7.jpg


thats where were up to now.

the reason ive stripped it is due to lots of bits of shell in the sump.

#3 conrod is very stiff on the crank. im quite surprised i managed to rag the fuck out of it for about 500 miles in that condition and it hasn't grenaded or turned blue.


next will be dropping the oil and leaving it to drain, then all the clutch / generator / pickup type stuff out, then split the cases.




if anyones got any contacts for someone who could paint the whole engine once ive had it vapor blasted i'd like to know.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Noxious89123]

Cool stuff
____________________
'06 Honda CBR125RW-6 ~ '00 Honda CBR600F-Y ~ '07 Honda CBR600RR-7 ~ Bikeless
'53 Ford Ka 1.3 ~ '03 Vauxhall Astra SRi 1.8 ~ '52 Vauxhall Astra SRi 2.2 ~ '53 Vauxhall Astra GSi

[lihp]

awesome

That is all
____________________
covent.gardens: lihp is my most favourite member ever

[Fazer Tom]

Awesome. I had my Kz400 engine vapor blasted, Looked amazing. When you have the cases blasted be sure to put up some pics before painting, I'd like to see how factory painted engines look afterwards.
____________________
(CBT 01/07/11. Theory, 21/05/12. MOD 1, 01/06/12. MOD 2, 3/08/12)

Past: (1981 CG125) (1992 ZZR250 x2) (1976 KZ400) (1993 400 Superfour) (2002 Triumph TT600) (1998 Fazer) (2001 CCM 636) (2000 CCM 604) (2007 Kawasaki Z750) (2005 Husqvarna SM450R) Current: (1989 Bandit 400)

[orac]

out of interest about how much meat will you have on the liners when you go to 59mm bore
____________________
Current rides - 2016 Triumph Street Triple Rx, 1994 Suzuki Bandit 400 VM, TGB 204 Classic 125cc
"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"

[CHR15]

dunno if im even doing that anymore. havent had much luck finding any of the pistons i need.

rare version of the fzr.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Knacker]

Hello there!
____________________
Current: Gsxr 600 Srad - GS125 - DT125
Previous: K1 GSXR 1000

[CHR15]

hello?



so, tomorrow ive got to drop off some parts for vapor blasting for another engine im doing, so i thought i'd be clever and get the gk cases split and sent to blast + paint. hahaha.


so yeah, ignition rotor

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1173Medium_zpsaeed5fbf.jpg


bangtidy impact gun

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1174Medium_zps9e18c7b9.jpg


using the precision engineering weight, overhang the engine to drain the oil

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1175Medium_zps23029bef.jpg

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1177Medium_zpse50fee15.jpg


didnt take much pics of the next bit as i was swearing and getting coated in oil; flip the enigne

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1180Medium_zpsff42499c.jpg

wizz out all the bolts, not forgetting the 2 hidden inside the oil filter.


suzuki give you handy things that you wind a bolt into to split the cases.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1181Medium_zpse7958404.jpg


except i couldn't split them because the alternator wouldnt come off.

i made a thing with 3 holes in it to put over the centre bolt, wind 3
bolts through and it should pop off.

if only. gotta take it work first thing tomorrow and get the 3 hole thing attached to my fuck off big 3 leg puller.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[orac]

is the the 3he pistons??

didnt take long to find at all if so
https://www.ebay.co.uk/itm/380602507156?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

as for the fly wheel
https://www.machinemart.co.uk/shop/product/details/cht248-13-pce-harmonic-balance-puller?da=1&TC=SRC-hub+puller
add and impact wrench and some heat and you should be laughing - works every time on my motors
____________________
Current rides - 2016 Triumph Street Triple Rx, 1994 Suzuki Bandit 400 VM, TGB 204 Classic 125cc
"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"

[trisers]

Will the camshaft with the iffy lobe be useable?

[CHR15]

i havnt geivne it a good enough going over yet.


yeah orac, there the ones. dont think im going to bother though. the liners are quite thin if you take them out to that size.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[orac]

i quick measure ofthe ones i have show between 1.4 and 1.6mm which i must agree is pretty thin. i was hoping the gsxr liners would be thicker. i have heard of the FZR liner being fitted with some modification to the block, some even fitting the 650 kit the 400 to give 465cc - it doable just depeneds how far you are willing to go
____________________
Current rides - 2016 Triumph Street Triple Rx, 1994 Suzuki Bandit 400 VM, TGB 204 Classic 125cc
"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"

[CHR15]

yeah, this engine isnt going to turn into some sort of test bed for wacky engine mods. i just want it to be a clean reliable motor.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Sload]

Really good read and nicely done. Can I ask what your day job is?
____________________
Honda Varadero >> Triumph Speed Four >> Honda CBR1100xx

[CHR15]

i design heath robinson-esk widgets for car factories. also do all sorts of weird and wonderful things mainly to do with industrial automation.


anyway, i broke my 3 leg puller trying to get the gen rotor off lol.

so ive ordered a harmonic balancer puller.

had a trip down to the blasting place today sans gk bits, turns out he also does 2pac painting, so i'll be sending the whole stripped engine to him for cleaning and painting back to as close to factory as he can get.

also picked up a new lhs engine cover on the way home from work.


some random pics of stripping the head

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1184Medium_zps8f13c200.jpg

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1185Medium_zps1dfc24fc.jpg

everything numbered and sorted.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1186Medium_zps587cc3b6.jpg


stripped

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1187Medium_zpsb88418cc.jpg

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1188Medium_zps4ce8e8fd.jpg


bits (minus cases) ready for paint

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1189Medium_zps376c95c1.jpg
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Noxious89123]

Phwoar... I love looking at bits of engine. Top thread!
____________________
'06 Honda CBR125RW-6 ~ '00 Honda CBR600F-Y ~ '07 Honda CBR600RR-7 ~ Bikeless
'53 Ford Ka 1.3 ~ '03 Vauxhall Astra SRi 1.8 ~ '52 Vauxhall Astra SRi 2.2 ~ '53 Vauxhall Astra GSi

[Fazer Tom]

https://www.dirtbikeaddicts.com/content/attachments/i-love-this-thread-so-much-jpg.9600/


____________________
(CBT 01/07/11. Theory, 21/05/12. MOD 1, 01/06/12. MOD 2, 3/08/12)

Past: (1981 CG125) (1992 ZZR250 x2) (1976 KZ400) (1993 400 Superfour) (2002 Triumph TT600) (1998 Fazer) (2001 CCM 636) (2000 CCM 604) (2007 Kawasaki Z750) (2005 Husqvarna SM450R) Current: (1989 Bandit 400)

[0l0dom0l0]

If that came lobe is shot, what about some 10mm lift cams?
____________________
CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.

[b.seare]

Hi, sorry to hi-jack this post a little, but I recently purchased a GSXR 400 gk73a exactly the same as Chris's and just been supplied by a member on this forum with a new set of carb O-ring. Just wondered if anyone can shed any light on any carb settings such as clip needle positions, idle screw is it just standard 1.5 turns out ? and any other things I should know ? Thanks. any help would be appreciated.

[CHR15]

the engine continued to troll me today.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1190Medium_zps8d861d0c.jpg

brand new harmonic puller, oxy/propane to warm it, tightening the puller with a 3 foot bar.

nothing.

not a sausage.

just bent the puller legs.


in the end i raged a bit and drilled a hole through the gen rotor.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1191Medium_zps9ce95412.jpg

wound the screws out and split the cases with the gen still on the crank.


cases are totally stripped now, bar the barrel studs because the tool fairy has borrowed my stud puller.

took #3 conrod off to assess the damage.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1192Medium_zps01351e15.jpg

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1193Medium_zps21e6c545.jpg

in the grand scheme of things the damage is good.


https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1194Medium_zpsd4f2b2d5.jpg

little bit of heating on the cap, but nothing bad.

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1196Medium_zps8d6ef924.jpg

journal is good.

good thing about thse engines is the oil pump comes to bits dead easy

https://i939.photobucket.com/albums/ad233/chris-bracey/GK73A/IMAG1195Medium_zps7e71e0b8.jpg

unfortunately its munched a few bits of shell and the rotors at badly pitted so a new one is needed.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Sload]

Cool pictures Is that a lobe pump? Not sure if the lighting is distorting the image. How bad is the pitting then, wouldn't think it would be too critical on a bike pump, are you wary of it cavitating and getting worse?
____________________
Honda Varadero >> Triumph Speed Four >> Honda CBR1100xx

[CHR15]

im wary of bits breaking off and getting sucked through the engine.

theres a mixture of pitting and bits of shell embedded in the outer rotor.

the end plate is also badly scored due to stuff getting jammed in long ways and reducing the end float to nothing.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Sload]

Cheers for the info, it's all educational. I'm a fitter by trade but have never really played with engines in depth, I really should read a book or two about it.
____________________
Honda Varadero >> Triumph Speed Four >> Honda CBR1100xx