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ZX7R Engine Rebuild Photo Heavy

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Bike Bunker
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PostPosted: 21:41 - 06 Mar 2013    Post subject: ZX7R Engine Rebuild Photo Heavy Reply with quote

So i picked up a zx7r from bedford over the weekend.

Pretty decent price...got it of a pretty cool chap on here.

Overall bike was not too bad, swing arm polished wheel no dinks front wheel/rear wheel/ headstock bearings all intact. all brakes worked (zx7rr fronts) with brembo m/c and levers most panels pretty tidy, 19k on clocks
mot's from birth to 2007 (last time it was on road)


Sprockets and chain as rusty as the tin man in wizard of oz.
carbon mudguards/air intakes/full micron system with Ti pipes and carbon can Entire system weighs under 10kg

Came with a spare engine (one on the v5) was told it works but not tested

Engine in bike was told big end bearing gone...however im slightly unsure so stripping both engines to build one stick it back on the road get an mot run it in and sell it on... oh did i mention it came with a maxton shock with full manual and a receipt for 565!!

Oh and the race engine (in the bike is tuned like F*** by muzzy titanium rods/pistons/rings bored out (not sure to what)

Anyway ...photo's


as i got her....

been down on this side (crash bung saved most of it) obviously on a track as the graze is so smooth its like its being sanded lol! Thumbs Up
http://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash4/p206x206/1727_10200877794526815_292278424_n.jpg

http://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/599070_10200877790286709_591323331_n.jpg

http://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash4/399419_10200877792286759_293712292_n.jpg

These forks are special track forks they get you in the min weight by holding their oil then after about half a mile it shits all the fluid passed the seals to weight save Wink...forks have some pitting marks also
http://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/576304_10200877794166806_2041151793_n.jpg

spare engine (road)
http://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/577977_10200877794286809_613202685_n.jpg

damaged side
http://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash4/480001_10200877795046828_1346740255_n.jpg

Head on muzzy engine

http://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/155912_10200877798966926_1152583865_n.jpg

carbon
http://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/734021_10200877800526965_1943962070_n.jpg

maxton
http://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash4/294323_10200877800326960_1361951285_n.jpg

carbon
http://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/544144_10200877800646968_2009382442_n.jpg
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moppy
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PostPosted: 22:13 - 06 Mar 2013    Post subject: Reply with quote

Fucking cool. One of my favourite bikes, so will be watching this with interest. You bought it off someone from BCF right? I think I saw the thread a while back, and was tempted, but no good with engines and stuff, so couldn't pull the trigger.
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Bike Bunker
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PostPosted: 22:23 - 06 Mar 2013    Post subject: Reply with quote

So plan is get the engines running fit the road one...sell the race one...dyno it to get the carbs set up and jetted correctly for new engine....clean it all p sort forks out, polish swing arm so you can use it to see how your knee sliders look.

First step drop engine out, removed plugs out of curiosity..... uh oh

http://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/522559_10200877801927000_925661034_n.jpg

didn't get any pictures of the steps along the way but the fuel in the carb looked like that shit you get in a tub and you push your fingers in to make fart noise's? for those who don't know it was greeny and a bit gunky and smelt rank!

spent most of the day with the bent crash bung.... after it stripped itself of thread but damaged the bot and thread on the bar in such away it would not catch ended up literally filing down the thread to get it out heap of shit!

anyway a pedal zx7r!

http://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/542640_10200877802607017_2013972470_n.jpg
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Bike Bunker
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PostPosted: 22:27 - 06 Mar 2013    Post subject: Reply with quote

moppy wrote:
Fucking cool. One of my favourite bikes, so will be watching this with interest. You bought it off someone from BCF right? I think I saw the thread a while back, and was tempted, but no good with engines and stuff, so couldn't pull the trigger.


well you will see the build so know how its built feel free to make an offer at the end Smile
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Fellony
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PostPosted: 22:37 - 06 Mar 2013    Post subject: Reply with quote

Wow this is great to see. Glad you like all the bells and whistles it comes with!

I can promise you i didnt crash that on a track! Testament to some of the smooth bedford roads Razz

Thumbs up so far. Sorry about the carbs!
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moppy
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PostPosted: 22:47 - 06 Mar 2013    Post subject: Reply with quote

Bike Bunker wrote:
moppy wrote:
Fucking cool. One of my favourite bikes, so will be watching this with interest. You bought it off someone from BCF right? I think I saw the thread a while back, and was tempted, but no good with engines and stuff, so couldn't pull the trigger.


well you will see the build so know how its built feel free to make an offer at the end Smile
Considering the amount of work that goes into most of these Show & Tell threads, I can't imagine anyone actually wanting to sell it after all that work!
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Bike Bunker
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PostPosted: 22:52 - 06 Mar 2013    Post subject: Reply with quote

nope ive promised myself it must go to fund a B1H
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moppy
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PostPosted: 11:51 - 11 Mar 2013    Post subject: Reply with quote

Wheres the weekend update damnit?!
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Rob Fzs
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PostPosted: 13:40 - 11 Mar 2013    Post subject: Reply with quote

expects full top to bottom engine rebuild...

gets plug change and engine dropped out :/
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Bike Bunker
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PostPosted: 17:52 - 11 Mar 2013    Post subject: Reply with quote

Rob Fzs wrote:
expects full top to bottom engine rebuild...

gets plug change and engine dropped out :/


id like to see where the spark plugs have being changed? im in middle of getting photos all on mac and writing up thread but with two engines being done at once its not so easy.
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Rob Fzs
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PostPosted: 18:12 - 11 Mar 2013    Post subject: Reply with quote

so you havnt even changed the plugs...

well what the fail.
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'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 Mod 2 Passed 09/06/2011

nowhere.elysium wrote: i know it's you, jew
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Bike Bunker
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PostPosted: 00:32 - 12 Mar 2013    Post subject: Reply with quote

Rob Fzs wrote:
so you havnt even changed the plugs...

well what the fail.


nope why change plugs before rebuilding an engine? i simply removed the plugs when i had 5 spare minutes to see the state of them they give a good indication to how the bike was running before it went bang and then you can narrow down the cause's Thumbs Up
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Bike Bunker
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PostPosted: 00:52 - 12 Mar 2013    Post subject: Reply with quote

ANYWAY!!!! the rebuild of the 'standard road engine... began...

sump off ...

http://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/64838_10200910038732900_888901913_n.jpg

Check timing and photo for when rebuilding so i know where it all goes 'timed'
http://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn1/74409_10200910040532945_250598082_n.jpg

http://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/320116_10200910039892929_274886630_n.jpg

'internal filter' or 'pickup' wasnt too bad you often find a fair amount off rubber in here from the cam chain guide being worn by the chain

http://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/p206x206/599116_10200910054853303_459803723_n.jpg


Cam's out if you do this take note of the part numbers os you know what is the exhaust and what is the inlet.

http://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/531562_10200910056733350_2077909728_n.jpg

clutch plates out...

http://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/482634_10200910057693374_1720230792_n.jpg

shims all nice and tidy
http://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-snc7/484726_10200910055973331_1532805533_n.jpg


Now i have to give him credit where its de the owner of the bike told me...the standard engine ran..so he was told and was fine....so far during taking it aart its being mint!!! the oil in there was stilll golden nothings being out of place no broken parts nothings worn or scored seems legit Thumbs Up


Ad again credit where its due.....he told me the muzzy engine in the bike he believes the big end bearing has gone and i remove the sump and walla.....
http://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/601199_10200910058293389_1980252292_n.jpg


FOUND MOST THAT BEARING IN THE SUMP!!

Ill get some pictures off some of the shard metal up tomorrow and the rest of the engine strip
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Carl_steveo
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PostPosted: 03:49 - 12 Mar 2013    Post subject: Reply with quote

Looking forward to seeing this progress. Thumbs Up
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moppy
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PostPosted: 11:09 - 12 Mar 2013    Post subject: Reply with quote

^ As above.
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Jambon
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PostPosted: 12:11 - 12 Mar 2013    Post subject: Reply with quote

Doing well so far, nice to see an honest seller too.
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Bike Bunker
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PostPosted: 18:16 - 12 Mar 2013    Post subject: Reply with quote

Jambon wrote:
Doing well so far, nice to see an honest seller too.


definitely i only stripped the engine he said 'worked' because of all the people who have said that and ive found half a piston in the pick up!


anyway ill have more photo's up tonight guys Very Happy
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moppy
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PostPosted: 09:47 - 13 Mar 2013    Post subject: Reply with quote

Bike Bunker wrote:
Jambon wrote:
Doing well so far, nice to see an honest seller too.


definitely i only stripped the engine he said 'worked' because of all the people who have said that and ive found half a piston in the pick up!


anyway ill have more photo's up tonight guys Very Happy

LIES!


http://lolblog.co.uk/wp-content/uploads/2008/08/lies.jpg
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Bike Bunker
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PostPosted: 15:54 - 13 Mar 2013    Post subject: Reply with quote

HAHAHAHA sorry iphone cable is buggered cant get another till later tonight or tomorrow to get photos on now -.- Thumbs Down Thumbs Down Thumbs Down
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Drake
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PostPosted: 20:36 - 13 Mar 2013    Post subject: Reply with quote

not heard of mobile uploads?
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moppy
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PostPosted: 13:48 - 15 Mar 2013    Post subject: Reply with quote

Just posting to say get a fucking move on! Evil or Very Mad
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Rob Fzs
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PostPosted: 13:51 - 15 Mar 2013    Post subject: Reply with quote

he's some shitty arsed kid that takes shit apart and then sells them as an even worse project on ebay, not seen a completed project by him yet.
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 Mod 2 Passed 09/06/2011

nowhere.elysium wrote: i know it's you, jew
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Bike Bunker
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PostPosted: 15:07 - 17 Mar 2013    Post subject: Reply with quote

http://www.bikechatforums.com/viewtopic.php?p=2693445


one completed project....also i have only ever sold project bikes when i moved units and did not have the space too keep the three i had at the time...........I just dont have the time to post on the internet all day lol

But if your not interested stop posting Thumbs Up
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Bike Bunker
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PostPosted: 15:33 - 17 Mar 2013    Post subject: Reply with quote

removed clutch basket ect

http://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/299929_10200946261758453_1984423477_n.jpg


on a side note this happened to my mates bike when he went down the curb!

http://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/576199_10200946263598499_502214672_n.jpg


Just looking through zx7r manual at carb settings as i have not checked but assume its had jets fitted above standard to take the engine changes/exhaust system and racing filter,
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bacon
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PostPosted: 01:24 - 18 Mar 2013    Post subject: Reply with quote

From memory I believe the stock jets are 170/180 (outer/inner), no shims on the needle, I'm struggling to remember if the pilot screw is 2, 2.5 or 3 turns out though haha.

edit: oh and I'm quite sure its 13mm float
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