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ZX7R Engine Rebuild Photo Heavy

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bacon
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PostPosted: 02:39 - 18 Mar 2013    Post subject: Reply with quote

And wtf is with that shock!!!!!! What bike is it??
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Bike Bunker
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PostPosted: 21:55 - 20 Mar 2013    Post subject: Reply with quote

the snapped shock came from a good mates honda hornet 600 quite a comical moment to be honest.....

anyway update: Thumbs Up

case's split:

came apart quite nicely.....again respect where its due owner told me this engine ran and was in good condition and its by far the nicest thing ive ever seen it actually looks as though t was rebuilt and not even ran before ive now stripped it again!

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash4/480470_10200966125055023_1070832982_n.jpg

pretty straight forward gear box, unlike some with a third centre shaft.

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash4/483842_10200966124495009_1774193306_n.jpg

pistons all perfectly fine not a teenie bit of scoring on them at all.

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash4/482274_10200966124575011_336089933_n.jpg

Both engines (well mostly) on the wagon, kind of regret doing both at the same time but sods law...

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/384777_10200966125295029_1319226380_n.jpg

gear box out all working fine moving perfectly no damage Very Happy

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/581723_10200966125215027_1314202236_n.jpg


for anyone who doesnt know this is the heaviest thing you can imagine...must weigh between 10kg on its own and it obviously doesnt look like it

crank:

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn1/524911_10200966128095099_262174282_n.jpg

never under estimate the cleaning power of this badboy :

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-snc7/5565_10200966126455058_1068068839_n.jpg

those are not score marks just where the cleaning fluid has ran from drying it out with the air line for speed

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash3/486012_10200966127455083_1842071664_n.jpg


nice bits out of the sump from the muzzy engine think more than one bearing went lol


https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/526815_10200966126615062_936378001_n.jpg


pretty much just parts washing the inside and all case's cleaning all the older gaskets off and then throwing it back together....then finish the other muzzy engine off aswell....
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moppy
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PostPosted: 22:08 - 20 Mar 2013    Post subject: Reply with quote

Nice update, got absolutely no idea what I'm looking at, but clearly things are happening Laughing
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wilz1234
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PostPosted: 09:06 - 21 Mar 2013    Post subject: Reply with quote

Coming along nicely Very Happy

Keep the pictures coming
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cmr64racing
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Joined: 21 Mar 2013
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PostPosted: 12:40 - 24 Mar 2013    Post subject: Reply with quote

Dude, ive tried to PM you but the ridiculous spam filter keeps blocking it...

Interested in the motor & shock.
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P.
Red Rocket



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PostPosted: 12:44 - 24 Mar 2013    Post subject: Reply with quote

cmr64racing wrote:
Dude, ive tried to PM you but the ridiculous spam filter keeps blocking it...

Interested in the motor & shock.


Just hit the "email" button below his posts Wink
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Fellony
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PostPosted: 22:16 - 31 Mar 2013    Post subject: Reply with quote

Been a while since I checked on your progress. Gutted to see may have been more than just the big end gone Sad

Still planning on just making one engine out of two? Your getting more out of it than I was expecting, so who knows?

Keep up the fantastic work. Really pleased to see this! Thumbs Up
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Bike Bunker
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PostPosted: 13:00 - 26 Apr 2013    Post subject: Reply with quote

hope this shit seals the crank!

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/537985_10201169617902217_1972803051_n.jpg

Picked up a gasket set from cradley every gasket that exists...with discount to guys there deffo recommend

New work bike!
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/400584_10201169617302202_577208642_n.jpg

Crank case's together

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc1/486661_10201169617742213_411052313_n.jpg

race engine has being mostly stripped has aftermarket con rods, teflon coated pistons ti piston rings NICE!
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P.
Red Rocket



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PostPosted: 09:14 - 27 Apr 2013    Post subject: Reply with quote

You used an actual gasket as well didn't you?
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CHR15
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Joined: 14 Jun 2008
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PostPosted: 11:01 - 27 Apr 2013    Post subject: Reply with quote

Not between the crankcase halves.
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damz
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PostPosted: 14:19 - 27 Apr 2013    Post subject: Reply with quote

did you have any trouble getting the engine off the frame? the bolt on mine is completely seized so having a nightmare getting it off.
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P.
Red Rocket



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PostPosted: 15:26 - 27 Apr 2013    Post subject: Reply with quote

CHR15 wrote:
Not between the crankcase halves.


Not needed?
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CHR15
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PostPosted: 15:33 - 27 Apr 2013    Post subject: Reply with quote

the two halves of the crankcase need to touch, otherwise the nice line bored main bearing housings wont be circular.
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P.
Red Rocket



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PostPosted: 15:34 - 27 Apr 2013    Post subject: Reply with quote

CHR15 wrote:
the two halves of the crankcase need to touch, otherwise the nice line bored main bearing housings wont be circular.


Makes sense! Cheers Thumbs Up
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Bike Bunker
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PostPosted: 19:52 - 28 Apr 2013    Post subject: Reply with quote

crank case's do not use gaskets also i had some trouble getting it out of the frame due to a bent frame sider....bits of shit! but once that was out hey presto Thumbs Up
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Bike Bunker
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PostPosted: 15:23 - 15 May 2013    Post subject: Reply with quote

bit of a better update:


after much wheelie fun, carb adjusting, and falling off...

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/945406_10201269771726000_1948154897_n.jpg

got back on track doing some zx7r stuff.....


engine less
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/179127_10201269771886004_1655623495_n.jpg

hour or so later....

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/942129_10201269774606072_1566252668_n.jpg

Engine much.


a job for another day:

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/941566_10201269772086009_551368570_n.jpg

These forks seals are really good for race bikes as you loose 1L of fork fluid during the race giving you a huge weight advantage

will this leak?

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/923324_10201269773326040_814619120_n.jpg

i put the sump on last due to its nightmare shape and to avoid cracking it when moving the lump...worked out really well.

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/180279_10201269773206037_1484017264_n.jpg


new engine mounts since the old frame slider mount had its thread stripped to get it out BALLLACHE!!!


carbs are really nice and clean

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/p206x206/264418_10201269775046083_1322101266_n.jpg


I needed a wonder machine to put them in and hey presto:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc1/944286_10201280050942974_1739916340_n.jpg

Please notice the colour of the water going in? light grey.......quick explanation i used 4litres of water and a 5th litre of water but a 10:1 ratio with a cleaning chemical.....thats why its light grey but once its all mixed its pretty much clear.....look after 5 minutes of 3 carbs being in there....

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc1/944389_10201280051222981_304545429_n.jpg

BLACK!
no i know these was not spotless but was 100% usable


clean and not clean :


https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/941752_10201280051782995_766260891_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/21103_10201280051942999_960651019_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash3/166054_10201269774646073_717548664_n.jpg

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash4/248180_10201269776006107_2095729460_n.jpg

few their of the strip ect ...so for those who think your carbs ned a clean do it! it takes no time to strip them and most place's charge £20-£30 to clean them for you go for it or buy a kit yourself Wink


NOW THE RACE MOTOR!!!

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/944256_10201269777446143_972853258_n.jpg

one beautiful light con rod (far from stock ....believe made by muzzy as are the cams and a few other parts....however one of the other conrods:

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/923012_10201269776806127_1247471169_n.jpg

For those who cant see or dont know the black burnt looking opart is what it looks...burnt its going to be alot more brittle now as its being heated up so much and is pretty much shit

As if thats not anoying enough ive got to replace a aftermarket conrod NOT CHEAP!

this is what has caused it...

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn1/935358_10201269776726125_223466658_n.jpg

now that is no shell bearing thats a scrap crank! the shell bearing must have gave way shearing into the crank with the conrod going round and round causing immense heat the conrod got fucked the crank got fucked and the bearing got....well...

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/526815_10200966126615062_936378001_n.jpg

R.I.P

disappointed the engine is pretty fucked as i wanted around £400 since contacting muzzy they told me the work they have done (i gave them art numbers) would have coat much more than what a standard zx7r is worth ...pretty precise pricing system!


so the engine with three amazing conrods and racing cams everything else fine but one fucked crank is for sale £200 takes it

back to the road bike.....£200 got me a fork seal set and fork oil engine oil chain and sprockets and brake fluid one to bleed the brembo brake system so its amazing and 2 for the hydraulic clutch


now to do

fit radiator, exhaust, carbs, clean air filter(k+N), put it all together and ride also alot of cleaning to get done especially the aftermarket downpipes Smile



https://cdn.superbwallpapers.com/wallpapers/cartoons/thats-all-folks-7172-1680x1050.jpg
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CHR15
Turbo nutter bastard



Joined: 14 Jun 2008
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PostPosted: 18:38 - 15 May 2013    Post subject: Reply with quote

Quote:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/944256_10201269777446143_972853258_n.jpg


there stock rods.

muzzy rods use a bronze bush in the little end and are either h beam or knife beam.

they also use cap screws for the big ends.
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Bike Bunker
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PostPosted: 21:16 - 15 May 2013    Post subject: Reply with quote

deffo not stock ive got a stock set in the other engine and they are completely different and weigh and aweful lot more
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CHR15
Turbo nutter bastard



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PostPosted: 21:43 - 15 May 2013    Post subject: Reply with quote

well, there not aftermarket.

there cast not forged and someones taken a polishing mop to them.

https://www.ebay.com/itm/ZX-7-ZX-7-ZX-7R-ZX-750-CONNECTING-ROD-191-1992-1993-1994-1995-1996-1997-1998-/170781648330?pt=Motorcycles_Parts_Accessories&hash=item27c36125ca&vxp=mtr
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Drake
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PostPosted: 10:12 - 16 May 2013    Post subject: Reply with quote

raped
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Jenks
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PostPosted: 10:52 - 16 May 2013    Post subject: Reply with quote

wonder if the engines nothing to do with muzzy then, and they are just blanking plates for the recirc system?
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CHR15
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PostPosted: 18:00 - 16 May 2013    Post subject: Reply with quote

Jenks wrote:
wonder if the engines nothing to do with muzzy then, and they are just blanking plates for the recirc system?



there blanking plates for the pair system. (or whatever kawasakis version is)


https://www.muzzys.com/block-off_plates/
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evoboy
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PostPosted: 18:06 - 16 May 2013    Post subject: Reply with quote

CHRI5= So much win.

Laughing
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Jenks
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PostPosted: 18:39 - 16 May 2013    Post subject: Reply with quote

Quote:
there blanking plates for the pair system. (or whatever kawasakis version is)


https://www.muzzys.com/block-off_plates/


thats wat i mean[/quote]
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Kris
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PostPosted: 08:49 - 17 May 2013    Post subject: Reply with quote

Muzzy rods look like this:

https://www.muzzys.com/catalog/cat_photos/15e.jpg
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